Formliner for forming a pattern in curable material and method of use

ABSTRACT

Features for formliners to form a decorative pattern in a curable material and methods of using the same are disclosed. An improved formliner is disclosed with substantially seamlessly connecting components that reduces the need for using adhesives for interconnecting a plurality of formliners in a pattern. Further, the formliner is configured to reduce and/or substantially eliminate visible seams in order to create a more natural appearance in a finished product of the curable material.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

Any and all applications for which a foreign or domestic priority claimis identified in the Application Data Sheet as filed with the presentapplication are hereby incorporated by reference under 37 CFR 1.57.

BACKGROUND Field

The present disclosure relates generally to formliners and methods ofusing the same. More specifically, the present disclosure relates to animproved formliner for creating a desired pattern in curable materialwhile minimizing visible seams in the curable material.

Description of the Related Art

Decorative masonry and concrete construction have become increasinglypopular in recent years. The façades of homes and other buildings thathad previously been constructed in very simple and plain concrete arenow being replaced with either decorative stone and brick or decorativeconcrete construction.

As a result of the increased demand for stone and brick work, variousimprovements have been made in stone and brick masonry and concreteconstruction. These improvements have lowered the cost for suchconstruction by decreasing the time or skill requirements previouslyneeded to perform such work.

For example, in stone and brick masonry, facings and floors have beentraditionally constructed by skilled artisans from individual units.However, recent advances have been made in the masonry art which allowartisans to more quickly and accurately perform stone or brick work. Inparticular, various panels, forms, and mounting systems have beendeveloped that allow individual units to be placed in precise geometricpatterns, thus eliminating much of the painstaking effort usuallyexpended by the artisan. This now allows generally unskilled artisans,such as the do-it-yourselfer, to create a high-quality product.

Perhaps more importantly for projects with a tighter budget, advances inconcrete construction now allow artisans to create a faux stone or brickappearance in concrete with a formliner. As a result, one may achievethe appearance of stone or brick without the associated cost.

A concrete and/or other curable material formliner generally comprisesan interior surface onto which concrete and/or other curable material ispoured. The interior surface of the formliner typically includes adesired pattern or shape that will be transferred to the concrete and/orother curable material to form a cured concrete and/or other curablematerial casting. In many cases, the formliner is lined up withadditional formliners to create a pattern over a wide area.

After the concrete and/or other curable material has cured, theformliners are removed from the exposed surface of the concrete and/orother curable material, thus revealing the desired pattern or shape.Such patterns or shapes can include faux stone or brick, wave patterns,emblems, etc.

SUMMARY

As noted above, in recent years, significant advances have been made inthe art of concrete and/or other curable material laying. Varioustechniques and equipment have been developed that allow for the creationof decorative patterns in the concrete and/or other curable material,especially a faux stone or brick appearance. The results of suchtechniques and equipment provide the appearance of stone, brick, orother pattern without the cost. The concrete and/or other curablematerial casting can be created in a horizontal (such as for tilt upconstruction) or vertical casting process, and can be pre-cast, orcast-at-site construction.

The present disclosure discloses an improved formliner with seamlesslyconnecting components that eliminates the need for using adhesives forinterconnecting a plurality of formliners in a pattern. Further, theformliner is configured to reduce and/or substantially eliminate visibleseams in order to create a more natural appearance in a finishedproduct.

A formliner can have at least one cell bound and/or circumscribed by asystem of ribs. The cell can include a decorative pattern to be createdin concrete and/or other curable material. The ribs can include anoverlapping section that overlays onto an overlapped section whenmultiple formliners are interconnected. The overlapping section can beconnected to the cell of the formliner via a channel and/or groove. Thechannel and/or groove can extend along a boundary or periphery of thecell between the cell and the ribs. The channel and/or groove can extendinto or past the decorative pattern in the cell. The channel and/orgroove can be sized and positioned to engage, accept, mate, and/orconnect with an edge of the overlapping section when the overlappingsection is overlaid onto the overlapped section. By positioning,inserting, and/or extending the edge of the overlapping section in/intothe channel, seams in curable material can be minimized and/orsubstantially eliminated (e.g., seams that would be formed in thecurable material by a free edge of the overlapping section such as anedge of the overlapping section not positioned in a channel and/orgroove when the overlapping section is overlaid onto the overlappedsection).

According to at least one of the formliners disclosed herein is therealization that in using multiple formliners, seams may be createdbetween the formliners where the formliners meet. For example, in orderto create a large pattern or casting with prior art formliners, theformliners are merely placed together using butt joints, thus creatingsignificant visible seams between the formliners. As a result, theappearance of the exposed surface of the concrete is compromised. Anunsightly seam is very easy to notice and takes a substantial amount oftime and effort to remove from cured concrete. Further, in large-scaleprojects, it may be too costly to re-work the cured concrete and/orother material in order to remove the seams. As such, the seams aresimply left in place resulting in an inferior concrete and/or othermaterial product.

Thus, the present disclosure discloses formliners for forming patternsand methods of use of the formliners that minimize, reduce, and/orsubstantially eliminate undesirable seams. For example, the formlinercan have one or more cells and one or more raised sections or ribs,wherein the formliner is shaped and configured to be interconnected withother such formliners to create a pattern or array of formliners whichnest with each other such that an applied material provides a naturalappearance and substantially does not show seaming between theformliners that were interconnected, connected, and/or assembled tocreate the pattern. As discussed herein, there are various features thatcan be incorporated into this broad conception of the formliner in orderto provide various features of the formliner. In the presentdescription, the disclosed features can optionally be incorporated intothe above-noted formliner and its method of use in any combination.Additionally, Applicants describe some of these features and methods inpatent applications, such as International Patent Application No.PCT/US2009/058489, filed Sep. 25, 2009, U.S. patent application Ser. No.12/406,896, filed Mar. 18, 2009, U.S. patent application Ser. No.12/850,510, filed Aug. 4, 2010, U.S. patent application Ser. No.12/238,294, filed Sep. 25, 2008, and U.S. Provisional Application No.62/116,407, filed Feb. 14, 2015, the entireties of each of which areincorporated herein by reference and made a part of this specification.

According to this disclosure, a formliner for creating a pattern incurable material includes one or more of the following: a cellcomprising a contact surface configured to face curable material in use,the contact surface comprising a decorative pattern to be created in thecurable material, the decorative pattern comprising a varying depth; arib system comprising a plurality of ribs extending along the cell andforming at least a part of a boundary of the cell; and/or a channelextending along at least a portion of the boundary of the cell, thechannel extending into the cell at least an extent of the varying depthof the decorative pattern at the boundary of the cell. The rib systemincludes one or more of the following: an overlapping section connectedwith the cell and comprising a first rib edge, the overlapping sectionconfigured to face the curable material in use; and/or an overlappedsection connected with the cell and comprising a second rib edge, atleast a portion of the overlapping section configured to overlay onto atleast a portion of the overlapped section. The at least a portion of thefirst rib edge extends into the channel when the at least a portion ofthe overlapping section overlays onto the at least a portion of theoverlapped section. The second rib edge extends along the boundary ofthe cell and toward a support surface to provide structural support tothe overlapped section and the overlapping section when the at least aportion of the overlapping section overlays onto the at least a portionof the overlapped section with the formliner in use.

According to this disclosure, the formliner further includes one or moreof the following: the channel connects the cell to the overlappedsection along the at least a portion of the boundary of the cell; thechannel connects the contact surface of the cell to the overlappedsection along the at least a portion of the boundary of the cell; thechannel has a width generally corresponding to a thickness of theformliner for the first rib edge to extend into the channel; the varyingdepth of the decorative pattern has a predetermined amplitude at theboundary of the cell corresponding to the extent of the varying depth atthe boundary of the cell, and wherein the first rib edge has an extentequal to or greater than the predetermined amplitude at the boundary ofthe cell; the varying depth of the decorative pattern has a maximumamplitude in the cell, and wherein the maximum amplitude of thedecorative pattern is greater than the extent of the varying depth atthe boundary of the cell; an extent of the overlapping section is lessthan an extent of the overlapped section; the channel extends toward thesupport surface less than the second rib edge extends toward the supportsurface when the at least a portion of the overlapping section overlaysonto the at least a portion of the overlapped section with the formlinerin use; the second rib edge contacts the support surface to providestructural support to the overlapped section and the overlapping sectionwhen the at least a portion of the overlapping section overlays onto theat least a portion of the overlapped section with the formliner in use,and wherein an exterior surface of the channel facing the supportsurface does not contact the support surface; further comprising aplurality of cells each comprising a contact surface configured to facethe curable material in use, wherein the plurality of ribs extend alongat least two cells of the plurality of cells and form at least parts ofboundaries of the at least two cells, wherein the channel extends alongat least portions of boundaries of the at least two cells, and whereinthe at least a portion of the first rib edge extends into the channelalong the at least portions of boundaries of the at least two cells whenthe at least a portion of the overlapping section overlays onto the atleast a portion of the overlapped section; the plurality of ribs isdisposed between the plurality of cells to form boundaries of theplurality of cells; the plurality of cells define a generallyrectangular shape; at least some of the plurality of cells havedifferent sizes; the plurality of cells comprise opposing ends, theplurality of cells being arranged in a plurality of rows with each layerhaving at least two cells disposed end-to-end; cells of a first row ofthe plurality of rows are offset from cells of a second row of theplurality of rows; the channel extends at substantially a same levelthrough at least one rib of the plurality of ribs between at least twocells of the plurality of cells; the first rib edge extends through theat least one rib of the plurality of ribs between the at least two cellsof the plurality of cells in the channel; the overlapping sectioncomprises an opening, and wherein the overlapped section is configuredto extend through the opening; the opening is formed at least partiallyin the first rib edge; a first formliner is configured to be assembledwith a second formliner by overlaying at least a portion of anoverlapping section of the second formliner onto at least a portion ofan overlapped section of the first formliner such that an exteriorsurface of the overlapping section of the second formliner issubstantially flush with exterior surfaces of a rib system of the firstformliner when the first and second formliners are assembled; the ribsystem further includes a plurality of non-overlap ribs; the rib systemincludes a transition zone between the non-overlap ribs and theoverlapped section, the transition zone connecting the overlappedsection with the non-overlap ribs; a first rib edge of the secondformliner is positioned adjacent to a transition zone of the firstformliner when the first and second formliners are assembled; thetransition zone comprises a varying cross-sectional profile increasingfrom the overlapped section to the non-overlap ribs; the overlappingsection of the second formliner comprises an opening, wherein theoverlapped section of the first formliner extends through the opening ofthe second formliner such that the opening of the second formliner isadjacent to the transition zone of the first formliner when the firstand second formliners are assembled; the first and second formliners areconfigured to be assembled with at least one other formliner byoverlaying at least a portion of an overlapping section of the at leastone other formliner onto at least an other portion of the overlappedsection of the first formliner such that at least a portion of a firstrib edge of the overlapping section of the at least one other formlinerextends into the channel of the first formliner; the overlapped sectionof the first formliner comprises a cutout such that a part of theoverlapped section of the first formliner corresponding to the cutout isnot overlapped by the overlapping section of the second formliner whenthe first and second formliners are assembled; the cutout of theoverlapped section of the first formliner is positioned at a corner ofthe first formliner, the corner of the first formliner formed by anintersection of ribs of the rib system of the first formliner; theoverlapped or the overlapping section of the formliner comprises atleast one cutout such that a part of the rib system directly faces thesupport surface corresponding to the cutout when the at least a portionof the overlapping section overlays onto the at least a portion of theoverlapped section with the formliner in use; the at least one cutout ofthe overlapped or overlapping section of the formliner is positioned atat least one corner of the formliner, the at least one corner of theformliner formed by an intersection of ribs of the rib system of theformliner; the channel extends throughout the at least a portion of anoverlapped section of the first formliner overlaid by the at least aportion of an overlapping section of the second formliner; theoverlapping section comprises a first wall, a second wall connected tothe first wall of the overlapping section, and a third wall connected tothe second wall of the overlapping section, wherein the overlappedsection comprises a first wall, a second wall connected to the firstwall of the overlapped section, and a third wall connected to the secondwall of the overlapped section, wherein the first wall of theoverlapping section is configured to overlap the third wall of theoverlapped section, wherein the second wall of the overlapping sectionis configured to overlap the second wall of the overlapped section, andwherein the third wall of the overlapping section is configured tooverlap the first wall of the overlapped section; the first, second, andthird walls of the overlapping and the overlapped sections are atsubstantially right angles to each other; the third wall of theoverlapping section comprises the first rib edge; the third wall of theoverlapped section comprises the second rib edge; an extent of the thirdwall of the overlapping section is less than an extent of the first wallof the overlapping section; exterior surfaces of the rib system areconfigured to face the curable material in use; at least some of theplurality of ribs are substantially polygonal shaped; the cell isgenerally a rectangular shape; the formliner comprises a first end and asecond end, the first end being formed to include a first finger jointpattern and the second end being formed to include a second finger jointpattern that is complementary to the first finger joint pattern, whereinthe first end is configured to be overlaid with the second end when theat least a portion of the overlapping section overlays onto the at leasta portion of the overlapped section; the decorative pattern comprises atextured pattern bounded by the rib system, wherein placing the curablematerial against the contact surface forms a textured surface in anexposed surface of the curable material where the contact surfacecomprising the textured pattern directly contacts the exposed surface ofthe curable material; the textured pattern comprises at least one ofbrick, wood, rock, stone, faux stone, cut stone, sand stone, ledgestone,fieldstone, castle rock, river rock, or slate; an extent of firstsection from the cell toward the first rib edge is less than an extentof the second section from the cell toward the second rib edge; and/orthe overlapping section has a first length from the cell toward thefirst rib edge and the overlapped section has a second length from thecell toward the second rib edge, and wherein the first length is aboutone fourth of the second length.

According to this disclosure, a formliner for use in creating a patternin curable material includes one or more of the following: a cellcomprising a base configured to face curable material in use, the baseconfigured to create a pattern on the curable material; a rib systemcomprising a plurality of ribs extending along the cell and forming atleast a part of a boundary of the cell; and/or a groove connecting atleast a part of the cell to at least one rib of the plurality of ribs,the groove configured to accept the first rib end in the groove. The ribsystem includes one or more of the following: a first section connectedwith the cell and comprising a first rib end, the first sectionconfigured to face the curable material in use; and/or a second sectionconnected with the cell and comprising a second rib end, at least aportion of the first section configured to overlap onto at least aportion of the second section. The at least a portion the first rib endis in the groove when the at least a portion of the first sectionoverlaps onto the at least a portion of the second section.

According to this disclosure, the formliner further includes one or moreof the following: the second rib end extends generally along a samedirection as the first rib end when the at least a portion of the firstsection overlaps onto the at least a portion of the second section; thesecond rib end extends generally along the boundary of the cell; thesecond rib end extends toward a support surface to provide structuralsupport to the first section and the second section when the at least aportion of the first section overlaps onto the at least a portion of thesecond section with the formliner in use; the second rib end contactsthe support surface to provide structural support to the second sectionand the first section when the at least a portion of the first sectionoverlaps onto the at least a portion of the second section with theformliner in use, and wherein an exterior surface of the groove facingthe support surface does not contact the support surface; the second ribend extends past the base of the cell when the at least a portion of thefirst section overlaps onto the at least a portion of the secondsection; an extent of the first section from the cell toward the firstrib end is less than an extent of the second section from the celltoward the second rib end; the first section has a first length from thecell toward the first rib end and the second section has a second lengthfrom the cell toward the second rib end, and wherein the first length isabout one fourth of the second length; the groove connects the cell tothe second section along at least a portion of the boundary of the cell;the groove connects the base of the cell to the second section along theat least a portion of the boundary of the cell; the groove has a widthgenerally corresponding to a thickness of the formliner for the firstrib end to be in the groove; the base has a contour along a generalextent of the base, the contour changing with a predetermined magnitudeat the boundary of the cell along the general extent of the base, andwherein the first rib end has an extent equal to or greater than thepredetermined magnitude; the contour has a maximum magnitude in thecell, and wherein the maximum magnitude of the contour is greater thanthe predetermined magnitude at the boundary of the cell along thegeneral extent of the base; an end of the groove lies in a differentplane from a plane corresponding to an edge of the second rib end, thedifferent plane and the plane corresponding to an edge of the second ribend extend generally along the base; further comprising a plurality ofcells each comprising a base configured to face the curable material inuse, wherein the plurality of ribs extend along at least two cells ofthe plurality of cells and form at least parts of boundaries of the atleast two cells, wherein the groove extends along at least portions ofboundaries of the at least two cells, and wherein at least a portion ofthe groove is configured to accept the first rib end in the groove alongthe at least portions of boundaries of the at least two cells when theat least a portion of the first section overlaps onto the at least aportion of the second section; the plurality of ribs are disposedbetween the plurality of cells to form boundaries of the cells; theplurality of cells define a generally rectangular shape; at least someof the plurality of cells have different sizes; the plurality of cellscomprise opposing ends, the plurality of cells being arranged in aplurality of rows with each layer having at least two cells disposedend-to-end; cells of a first row of the plurality of rows are offsetfrom cells of a second row of the plurality of rows; the groove extendsat substantially a same level through at least one rib of the pluralityof ribs between at least two cells of the plurality of cells; the firstrib end extends through the at least one rib of the plurality of ribsbetween the at least two cells of the plurality of cells in the groove;the first section comprises an opening, and wherein the second sectionis configured to extend through the opening; the opening is formed atleast partially in the first rib end; a first formliner is configured tobe connected with a second formliner by overlapping at least a portionof a first section of the second formliner onto at least a portion of asecond section of the first formliner such that an exterior surface ofthe first section of the second formliner is substantially flush withexterior surfaces of a rib system of the first formliner when the firstand second formliners are assembled; the rib system includes a pluralityof internal ribs; the rib system includes a transition zone between theinternal ribs and the second section, the transition zone connecting thesecond section with the internal ribs; a first rib end of the secondformliner is positioned adjacent to a transition zone of the firstformliner when the first and second formliners are assembled; thetransition zone comprises a varying cross-sectional profile increasingfrom the second section to the internal ribs; the first section of thesecond formliner comprises an opening, wherein the second section of thefirst formliner extends through the opening of the second formliner suchthat the opening of the second formliner is adjacent to the transitionzone of the first formliner when the first and second formliners areassembled; the first and second formliners are configured to beconnected with at least one other formliner by overlapping at least aportion of a first section of the at least one other formliner onto atleast an other portion of the second section of the first formliner; atleast a portion of a first rib edge of the first section of the at leastone other formliner extends into the groove of the first formliner; thesecond section of the first formliner comprises a cutout such that apart of the second section of the first formliner corresponding to thecutout is not overlapped by the first section of the second formlinerwhen the first and second formliners are connected; the cutout of thesecond section of the first formliner is positioned at a corner of thefirst formliner, the corner of the first formliner formed by anintersection of ribs of the rib system of the first formliner; the firstor second section of the formliner comprises at least one cutout suchthat a part of the rib system of the formliner does not overlap an otherpart of the rib system corresponding to the cutout when the at least aportion of the first section overlays onto the at least a portion of thesecond section with the formliner in use; the at least one cutout of thefirst or second section of the formliner is positioned at at least onecorner of the formliner, the at least one corner of the formliner formedby an intersection of the plurality of ribs of the rib system of theformliner; the groove extends throughout the at least a portion of asecond section of the first formliner overlaid by the at least a portionof a first section of the second formliner; the first section comprisesa first wall, a second wall connected to the first wall of the firstsection, and a third wall connected to the second wall of the firstsection, wherein the second section comprises a first wall, a secondwall connected to the first wall of the second section, and a third wallconnected to the second wall of the second section, wherein the firstwall of the first section is configured to overlap the third wall of thesecond section, wherein the second wall of the first section isconfigured to overlap the second wall of the second section, and whereinthe third wall of the first section is configured to overlap the firstwall of the second section; the first, second, and third walls of thefirst and second sections are at substantially right angles to eachother; the third wall of the first section comprises the first rib end;the third wall of the second section comprises the second rib end; anextent of the third wall of the first section is less than an extent ofthe first wall of the first section; exterior surfaces of the rib systemare configured to face the curable material in use; at least some of theplurality of ribs are substantially polygonal shaped; the cell isgenerally a rectangular shape; the formliner comprises a first end and asecond end, the first end being formed to include a first finger jointpattern and the second end being formed to include a second finger jointpattern that is complementary to the first finger joint pattern, whereinthe first end is configured to be overlaid with the second end when theat least a portion of the first section overlaps onto the at least aportion of the second section; the pattern comprises a textured patternbounded by the rib system, wherein placing the curable material againstthe base and the rib system forms a textured surface in an exposedsurface of the curable material where the base comprising the texturedpattern directly contacts the exposed surface of the curable material;and/or the textured pattern comprises at least one of brick, wood, rock,stone, faux stone, cut stone, sand stone, ledgestone, fieldstone, castlerock, river rock, or slate.

According to this disclosure, a formliner for use in creating adecorative pattern in curable material includes one or more of thefollowing: a cell comprising a base configured to face curable materialin use; and/or a channel connected to at least a portion of the cell atthe base; and a rib system extending along the cell, the rib systemcomprising. The rib system includes one or more of the following: afirst wall extending upwardly from the base; a second wall extendingfrom first wall substantially in parallel with an extent of the base; athird wall extending downwardly from the second wall toward the extentof the base; a fourth wall extending upwardly from the channel; and afifth wall extending from fourth wall substantially in parallel with theextent of the base; and/or a sixth wall extending downwardly from thefifth wall toward the extent of the base. The first, second, and thirdwalls are configured to overlap the fourth, fifth, and sixth walls suchthat at least a portion of the third wall extends into the channel.

According to this disclosure, the formliner further includes one or moreof the following: the first wall is configured to overlap the sixthwall; the second wall is configured to overlap the fifth wall; the thirdwall is configured to overlap the fourth wall; an extent of the firstwall is less than an extent of the sixth wall; an extent of the thirdwall is less than an extent of the fourth wall; an extent of the fourthwall is less than an extent of the sixth wall; an extent of the fifthwall is less than an extent of the second wall; at least a part of thethird wall is configured to extend into a groove when the first, second,and third walls overlap the fourth, fifth, and sixth walls; walls of therib system form one or more polygonal shapes; further comprising aplurality of cells, wherein the rib system comprises a plurality ofribs, and wherein the plurality of ribs are disposed between theplurality of cells to form a plurality of boundaries of the plurality ofcells; the channel extends through at least two cells of the pluralityof cells; the at least a portion of the third wall extends along the atleast two cells of the plurality of cells in the channel when the first,second, and third walls overlap the fourth, fifth, and sixth walls; thethird wall comprises at least one opening, and wherein at least one ribof the plurality of ribs extends through the opening when the first,second, and third walls overlap the fourth, fifth, and sixth walls; atleast some of the plurality of cells define a generally rectangularshape; at least some of the plurality of cells are of different sizes;the plurality of cells comprise opposing ends, the plurality of cellsbeing arranged in a plurality of rows with each row having at least twocells disposed end-to-end; cells of a first row of the plurality of rowsare offset from cells of a second row of the plurality of rows; theformliner comprises a first end and a second end, the first end beingformed to include a first finger joint pattern and the second end beingformed to include a second finger joint pattern that is complementary tothe first finger joint pattern, wherein the first end is configured tobe overlaid with the second end; the base comprises a textured patternbounded by the rib system, wherein placing the curable material againstthe base and the rib system forms a textured surface in an exposedsurface of the curable material where a contact surface comprising thetextured pattern directly contacts the exposed surface of the curablematerial; the textured pattern comprises at least one of brick, wood,rock, stone, faux stone, cut stone, sand stone, ledgestone, fieldstone,castle rock, river rock, or slate; the textured pattern connects withthe first wall; and/or the first wall, the second wall, and the thirdwall are configured to face the curable material in use when the first,second, and third walls overlap the fourth, fifth, and sixth walls.

According to this disclosure, a method for assembling formlinersincludes one or more of the following: connecting a first formliner witha second formliner by overlaying at least a portion of an overlappingsection of a rib of the second formliner onto at least a potion of anoverlapped section of a rib of the first formliner, the overlappingsection of the rib of the second formliner configured to face curablematerial; and/or while connecting the first formliner with the secondformliner, positioning at least a potion of a first rib edge of theoverlapping section of the rib of the second formliner into a groove ofthe first formliner, the groove of the first formliner extending betweenthe rib of the first formliner and a cell of the first formliner, thecell of the first formliner configured to face curable material in useand comprising a decorative pattern to be created in the curablematerial. The decorative pattern comprises a varying depth, the grooveextending into the cell at least an extent of the varying depth of thedecorative pattern proximate to the rib of the first formliner.

According to this disclosure, the method further includes one or more ofthe following: the first rib edge extends into the groove substantiallythe extent of the varying depth of the decorative pattern; positing asecond rib edge of the rib of the first formliner against a supportsurface to provide structural support to the overlapped section of thefirst formliner and the overlapping section of the second formliner;placing the curable material against exterior surfaces of the first andsecond formliners to create the decorative pattern in the curablematerial; while connecting the first formliner with the secondformliner, further comprising overlaying an opening of the overlappingsection of the rib of the second formliner onto the at least a portionof the overlapped section of the rib of the first formliner; positioningthe opening of the overlapping section of the rib of the secondformliner adjacent to a transition zone of the rib of the firstformliner, the transition zone having a varying profile that connectsthe overlapped section of the rib of the first formliner with anon-overlap section of the rib of the first formliner, wherein thenon-overlap section of the rib of the first formliner is not overlappedby the overlapping section of the rib of the second formliner; whileconnecting the first formliner with the second formliner, furthercomprising positioning a part of the rib of the second formliner over acutout in the overlapped section or the overlapping section of the ribof the first formliner such that the part of the rib of the secondformliner does not overlap the rib of the first formliner; connectingthe first and second formliners with at least one other formliner byoverlaying at least a portion of an overlapping section of a rib of theat least one other formliner onto at least an other portion of theoverlapped section of the rib of the first formliner; while connectingthe first, second, and at least one other formliners, positioning atleast a portion of a first rib edge of the overlapping section of therib of the at least one other formliner into the groove of the firstformliner; connecting the first, second, and at least one otherformliners with a fourth formliner by overlaying at least a portion ofan overlapping section of a rib of the fourth formliner onto at least afurther other portion of the overlapped section of the first formliner;while connecting the first, second, at least one other, and fourthformliners, positioning at least a portion of a first rib edge of theoverlapping section of the rib of the fourth formliner into the grooveof the first formliner; while connecting the first, second, at least oneother, and fourth formliners, positioning at least an other portion ofthe first rib edge of the overlapping section of the rib of the fourthformliner into a groove of the second formliner, the groove of thesecond formliner extending between the rib of the second formliner and acell of the second formliner, the cell of the second formlinerconfigured to face the curable material and comprising the decorativepattern to be created in the curable material; while connecting thefirst, second, at least one other, and fourth formliners, positioning atleast a further portion of the first rib edge of the overlapping sectionof the rib of the fourth formliner into a groove of the at least oneother formliner, the groove of the at least one other formlinerextending between the rib of the at least one other formliner and a cellof the at least one other formliner, the cell of the at least one otherformliner configured to face the curable material and comprising thedecorative pattern to be created in the curable material; and/or whileconnecting the first, second, at least one other, and fourth formliners,positioning a part of the overlapping section of the rib of the fourthformliner onto a cutout in the overlapping section or the overlappedsection of the rib of the at least one other formliner such that thepart of the overlapping section of the rib of the fourth formlinerdirectly faces the overlapped section of the first formliner.

A method is also provided for transferring a decorative pattern to anexposed surface of concrete and/or other curable material. The methodcomprises providing a plurality of formliners, each formliner comprisingone or more shaped regions being bounded by ridges, each formlinerdefining overlapped ridges and overlapping ridges. The method cancomprise engaging a first formliner with a second formliner byoverlaying overlapping ridges of the second formliner onto overlappedridges of the first formliner. For example, the method can includeabutting an opening formed in the overlapping ridge of the secondformliner with a transition zone formed in the first formliner, thetransition zone being formed between the overlapped ridge and anon-overlap ridge of the first formliner. The method can also includeplacing an edge or end of an overlapping ridge into a groove or channelformed in a shaped region or cell when the overlapping ridge is placedover or onto the overlapped ridge. The method can also comprise placingthe curable material against the first and second formliners, forexample, to transmit a decorative pattern formed by the shaped regionsof the first and second formliners to the curable material.

A formliner can include non-overlap or non-overlapping ridges and atleast one opening formed in the overlapping ridges. Thus, the method canfurther comprise overlaying the overlapping ridges of the secondformliner onto the overlapped ridges of the first formliner with anon-overlap ridge of the first formliner extending from an opening ofthe overlapping ridges of the second formliner. The non-overlap ridge ofthe first formliner can be interconnected with and extend from theoverlapped ridge of the first formliner.

The non-overlap ridge of the first formliner can be separated from theoverlapped ridge of the first formliner by a transition zone formed inthe second formliner, and the method further comprises abutting theopening of the first formliner with the transition zone of the secondformliner. The overlapping ridge and the non-overlap ridge can havegenerally the same exterior cross-sectional profile such that theexterior surfaces of the overlapping ridge and the non-overlap ridge aresubstantially flush when the first and second formliners are assembled.The opening can be formed as an open end of the overlapping ridge of thesecond formliner.

The overlapping ridges of the second formliner can define an interiorcross-sectional profile that is greater than an exterior cross-sectionalprofile of the overlapped ridges of the first formliner. The method cancomprise engaging a third formliner with the first formliner and thesecond formliner. The third formliner can comprise overlapping ridgesand overlapped ridges. At least one of the first, second, or thirdformliners can comprise a sub-overlapped ridge section that defines anexterior cross-sectional profile that is less than an interiorcross-sectional profile of the overlapped ridges.

For example, the sub-overlapped ridge section can be formed along acorner of a boundary of the at least one of the first, second, or thirdformliners. The method can comprise overlaying an overlapped ridge ontothe sub-overlapped ridge section. Thus, the least one of the first,second, or third formliners can comprise the sub-overlapped ridgesection formed along a corner of a boundary of the least one of thefirst, second, or third formliners, and the other formliners of thefirst, second, or third formliners can overlap the least one of thefirst, second, or third formliners at the sub-overlapped ridge section.

The formliners can include at least one row with a projecting cellbordered in at least one adjacent row with a non-projecting cell, andthe method can comprise engaging the first formliner and the secondformliner with a projecting cell in a first row of the first formlinerbeing positioned adjacent to a non-projecting cell in a first row of thesecond formliner and a projecting cell in a second row of the secondformliner being positioned adjacent to a non-projecting cell in a secondrow of the first formliner.

The method can further include interconnecting a first formliner with asecond formliner by overlaying a first section of a rib of the secondformliner onto a second section of a rib of the first formliner suchthat the second section of the rib of the first formliner is nestedwithin a recess of the first section of the rib of the second formliner;and positioning an exterior surface of the first section of the rib ofthe second formliner flush with an exterior surface of a first sectionof the rib of the first formliner upon nesting of the second section ofthe first formliner within the first section of the second formliner.

The method can further include interconnecting another formliner withthe first and second formliners by overlaying at least one of the firstsection of the rib of the first formliner or a first section of the ribof the second formliner onto a second section of a rib of the otherformliner. Further, the method can comprise positioning an exteriorsurface of a first section of the rib of the other formliner flush withthe exterior surface of the first section of the rib of one of the firstor second formliner.

The method can include interconnecting a third formliner with the firstand second formliners by overlaying a first section of the thirdformliner onto at least one of the second section of the rib of thefirst formliner or a second section of the rib of the second formliner.The method can further comprise interconnecting a fourth formliner withthe first, second, and third formliners by overlaying a first section ofthe fourth formliner onto at least one of the second section of the ribof the first formliner, a second section of the rib of the secondformliner, or a second section of the rib of the third formliner. Themethod can comprise positioning an exterior surface of a first sectionof the rib of the fourth formliner flush with the exterior surface ofthe first section of the rib of one of the first, second, or thirdformliner.

Additionally, the method can include mating an opening in the firstsection of the first formliner against a transition zone of the secondformliner such that visible seams in the decorative pattern areminimized when the first formliner and the second formliner areinterconnected in use. The transition zone can be formed between thefirst and second sections of the rib of the second formliner. Further,the opening can be formed as an open end of the first section of thefirst formliner.

The foregoing is a summary and contains simplifications, generalization,and omissions of detail. Those skilled in the art will appreciate thatthe summary is illustrative only and is not intended to be in any waylimiting. Other aspects, features, and advantages of the devices and/orprocesses and/or other subject matter described herein will becomeapparent in the teachings set forth herein. The summary is provided tointroduce a selection of concepts in a simplified form that are furtherdescribed below in the Detailed Description. This summary is notintended to identify key features or essential features of any subjectmatter described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive features will be described withreference to the following figures, wherein like reference numeralsrefer to like parts throughout the various figures, unless otherwisespecified.

FIGS. 1-2 are top perspective views of a formliner.

FIGS. 3-4 are bottom perspective views of the formliner of FIGS. 1-2.

FIG. 5 is a top view of the formliner of FIGS. 1-2.

FIG. 6 is a bottom view of the formliner of FIGS. 1-2.

FIG. 7 is a detailed view of a portion of the formliner of FIGS. 1-2along the line 7-7 as indicated in FIG. 2.

FIG. 8 is a detailed view of a portion of the formliner of FIGS. 1-2along the line 8-8 as indicated in FIG. 3.

FIG. 9 is a detailed view of a portion of the formliner of FIGS. 1-2along the line 9-9 as indicated in FIG. 5.

FIG. 10 is a cross-section view of a portion of the formliner of FIGS.1-2 as taken along the line 10-10 as indicated in FIG. 5.

FIG. 11 is a cross-section view of a portion of the formliner of FIGS.1-2 as taken along the line 11-11 as indicated in FIG. 5.

FIG. 12 is a cross-section view of a portion of the formliner of FIGS.1-2 as taken along the line 12-12 as indicated in FIG. 5.

FIG. 13 is a cross-section view of a portion of the formliner of FIGS.1-2 as taken along the line 13-13 as indicated in FIG. 6.

FIG. 14 is a top perspective view of an assembly of formliners.

FIG. 15 is a bottom perspective view of the assembly of FIG. 14.

FIG. 16 is a cross-section view of a portion of the assembly of FIG. 14as taken along the line 16-16 as indicated in FIG. 14.

FIG. 17 is a cross-section view of a portion of the assembly of FIG. 14as taken along the line 17-17 as indicated in FIG. 14.

FIG. 18 is a cross-section view of a portion of the assembly of FIG. 14as taken along the line 18-18 as indicated in FIG. 14.

FIG. 19 is a cross-section view of a portion of an other assembly astaken along the line 18-18 as indicated in FIG. 14.

FIG. 20 is an exploded view of an assembly of two formliners.

FIG. 21 is an exploded view of an assembly of three formliners.

FIG. 22 is a perspective view of an assembly of a framework and severalformliners to be used with the framework for forming a pattern in acurable material.

DETAILED DESCRIPTION

While the present description sets forth specific details of variousfeatures, it will be appreciated that the description is illustrativeonly and should not be construed in any way as limiting. Furthermore,various applications of such features and modifications thereto, whichmay occur to those who are skilled in the art, are also encompassed bythe general concepts described herein.

As generally discussed above, formliners of the present inventions areadvantageously configured in order to enhance the aesthetic finish of aconcrete or other curable material structure. In particular, formlinersdisclosed herein can be used to create a natural, seamless appearance ofbrick, stone, and other types of materials in a concrete or othercurable material structure.

In contrast to prior art formliners that produce an inferior qualityproduct, the structures of the formliner disclosed herein, which canalso be referred to as a panel or sheet, allow the formliner to createdecorative patterns that are visually superior to results providedthrough the prior art. These significant advantages are due at least inpart to the nesting arrangement of the variable size channels of theformliner disclosed herein such as, for example, various parts of theformliner having corresponding features or parts that can mate, connect,or overlay with each other to form a desired formliner assembly. Inparticular, the formliner can comprise one or more relatively largerinterconnection sections and one or more relatively smallerinterconnection sections such that a plurality of formliners can beinterconnected at their respective large and small interconnectionsections. When interconnected, the plurality of formliners can defineone or more generally continuous dimensions or shapes of raised portionsthereof. For example, the large and small interconnection sections canbe configured as nesting semi-cylinders or semi-polygons (e.g., polygonsnot closed on one or more sides) that form a rib structure. Additionaladvantages and features of the formliner are discussed further below.

It is contemplated that the formliner can be attached to anotherformliner and/or a form work by means of an adhesive. The adhesive canbe disposed on a rear surface or back of the formliner and/or onto afront surface of the formliner. For example, the adhesive can bedisposed on the front surface along a rib or ridge that will be overlaidby a portion of another formliner. The adhesive can be applied tobutt-ends of formliners (e.g., sections that do not overlap as discussedherein).

The adhesive can be applied to the formliner at the site. For example,the adhesive can be applied or sprayed onto the formliner. The formlinercan comprise an adhesive that can be activated or exposed in order toenable adhesive attachment of the formliner to another formliner or to aform work. The adhesive can be pre-applied to the formliner and can beexposed by removing a cover strip or activated by dampening with aliquid such as water or otherwise. As such, by peeling away a coverstrip or by providing moisture to the adhesive, the adhesive can beactivated to adhesively attach the formliner to another formliner or toa form work. As noted above in this manner, the formliner can besecurely attached, engaged, mated, or connected to another formliner ina pattern and/or to a form work to facilitate handling and placement ofthe formliner.

The formliner and formliner components disclosed herein can bemanufactured using any of a variety of processes. For example, it iscontemplated that some formliners can be formed using a sheet and avacuum forming operation. Other manufacturing processes such asinjection molding, stamping, extrusion, etc. can also be used. Theformliner or formliner components can be cut and shaped using anysuitable method, including shear and/or laser cutting processes.

FIG. 1 is a top perspective view of a panel, sheet, or formliner 100from one side of the formliner 100, while FIG. 2 is a top perspectiveview of the formliner 100 from the opposite side of the formliner 100.Referring to FIGS. 1 and 2, the formliner 100 can comprise a pluralityof channels, ridges, or ribs 102. The ribs 102 can be a raised portionof the formliner 100. The ribs 102 can define an outer perimeter of theformliner 100. Additionally, the ribs 102 can extend inwardly to formone or more recesses or cells 104.

The cells 104 can comprise a recessed portion of the formliner 100. Therecessed portion of the cell 104 can be configured to receive a curablematerial to which a pattern of the formliner can be conferred ortransferred. The cells 104 can be uniformly sized. For example, thecells 104 can be rectangularly shaped. As discussed below, the formliner100 can implement other shapes, depths, and sizes of the cells 104.

As shown, the cells or recesses 104 can be arranged in rows or layers.As will be discussed further below, the cells or recesses 104 of a givenrow can be offset with respect to cells or recesses of an adjacent orneighboring row. In this regard, a plurality of formliners 100 can beinterconnected along ends thereof in such a way as to reduce any visibleappearance of a seam between interconnected formliners. The offsetconfiguration of the cells or recesses 104 can aid in concealing orhiding any seaming between formliners as well as provide a correspondingassembly joints for the formliners that conform to a desired pattern(e.g., rectangular cells 104).

Additionally, the cells 104 of adjacent rows can be offset from eachother such that at opposing ends of the formliner 100, some of the cells104 protrude at the end. In this regard, the rows can be formed toinclude projecting and non-projecting cells 104. The projecting cellscan be considered to be complete or whole cells. In other words, theprojecting cells may not be smaller in size than other cells 104 of thepattern even though the offset configuration of the cells 104 causes theprojecting cells to protrude at one side or end of the formliner 100. Aswill be discussed further below, the projecting cells of the pattern canbe interconnected with projecting cells of another formliner.

The formliner 100 can be used to create a faux brick and/or masonrypattern on a concrete structure. The formliner 100 can define a panelboundary 115 bounding the plurality of cells 104 by a plurality ofsides. The top side of the formliner 100 may be positioned such that itcan be pressed into fresh concrete. This can be accomplished by placingthe formliner 100 against an exposed surface of fresh concrete.Otherwise, this can be accomplished by affixing a lower surface of theformliner 100 to an interior wall of a pattern, casting, or formwork(e.g., framework) before concrete is poured into the pattern, casting,or formwork. In either case, a material, such as concrete can be placedagainst the decorative pattern of the formliner 100 defined by the ribs102 and the cells 104 in order to transfer the decorative pattern to theexposed surface of the material as the material cures.

The formliner 100 may include one or more ribs 102 that together form arib system or network. The ribs 102 may be connected to or otherwisecoupled with, and extend or project away from, one or more base segmentsor base 103 (e.g., web, contact surface, plane, base plane) of, forexample, a cell 104. The base 103 may be generally flat or planar withthe ribs 102 projecting from a side of the base 103. The ribs 102connecting with the base 103 may form perimeters or peripheries 210 ofthe cells 104 (e.g., inside a cell 104) as discussed herein and inparticular, in reference to FIG. 11. The base 103 can have an extentalong the cell 104. For example, the extent of the base 103 may besubstantially perpendicular to the walls of the ribs 102 as discussedherein. The extent of the base 103 may be along a longitudinal dimensionof the base 103. For example, the extent of the base 103 may be thelength between two peripheries 210 illustrated in FIG. 11.

The base 103 can have a desired textured pattern as discussed herein.The ribs 102 form a rib system 112 of the formliner 100. The rib system112 and the base 103 can define or form a cell 104. There may be one ormore cells 104. As shown, there are sixteen cells 104. However, theremay be fewer or more cells 104. The cells 104 can be of the same,similar, and/or different size or dimensions. The cells 104 may bespaces into which a curable material, such as concrete, may be poured.It is understood that not every instance of a feature of the formlineris labeled in the various figures. For example, only some of the cells104 are labeled in FIGS. 1-2, however it is understood that there areother cells 104 as illustrated that, for purposes of clarity, are notlabeled. Similarly, only some of the ribs 102 are labeled in FIGS. 1-2for clarity. This may be true for other features of the formliner inthis or other figures where fewer than all of those features shown inthe respective figures are labeled with callouts.

The ribs 102 may have varying shapes, sizes and configurations. Asshown, the ribs 102 extend along and form a boundary 115 of theformliner 100 as well as a boundary 115 for the cells 104. The boundary115 may be located generally on the sides of the formliner 100. The ribs102 that form the boundary 115 may include one or more overlappedsections 120 (e.g., second sections) and one or more overlappingsections (e.g., first sections) 130. As shown, the overlapped section120 extends along two adjacent portions of the boundary 115, while theoverlapping section 130 extends along the two other adjacent portions ofthe boundary 115, as further described below. The overlapped sections120 and the overlapping sections 130 may have various configurations asdiscussed in further detail herein, for example with respect to FIGS.16-19. As is further discussed, the configurations of the sections 120,130 may allow for a first formliner 100 to meet or otherwise couple withcomplementary portions of a second formliner 100. Further detail of thecoupling of multiple formliners together is discussed herein, forexample with respect to FIGS. 14-22.

The formliner 100 may have corners. As shown, the formliner may have afirst corner 141, a second corner 142, a third corner 143 and a fourthcorner 144. The four corners 141, 142, 143, 144 may also be located ator along the boundary 115 of the formliner. The four corners 141, 142,143, 144 may be located at the ends of respective overlapped sections120 and/or overlapping sections 130. As shown, the overlapped section120 may extend along and form the boundary 115 from the first corner 141to the second corner 142. As further shown, the overlapped section 120may extend along and form the boundary 115 from the first corner 141 tothe fourth corner 144. Correspondingly, the overlapping section 130 mayextend along and form the boundary 115 from the third corner 143 to thefourth corner 144. As further shown, the overlapping section 130 mayextend along and form the boundary 115 from the third corner 143 to thefourth corner 144.

The boundary 115 and the various sections or portions thereof may extendin a variety of directions and have a variety of contours. As shown, theoverlapping section 130 extending from the third corner 143 to thefourth corner 144 may be in a first fingerjoint pattern. Similarly, theoverlapped section 120 extending from the first corner 141 to the secondcorner 142 may be in a second (corresponding) fingerjoint pattern asshown that is opposite from and complementary to the first fingerjointpattern. The complementary boundary portions, whether fingerjoint orother patterns or contours, may allow two or more formliners to besubstantially seamlessly assembled together. The boundary 115 may alsobe straight. As shown, the overlapping section 130 may extend from thesecond corner 142 to the third corner 143 in a generally straight orunbent fashion without any turns, bends, or corners. The overlappedsection 120 may extend from the fourth corner 144 to the first corner141 in a similarly straight manner as shown.

The various corners 141, 142, 143, 144 of the formliner 100 may belocations where the various sections intersect or are otherwise adjacentto each other. As shown, the first corner 141 may be a location wherethe overlapping section 130 intersects with or otherwise approaches theoverlapped section 120. The second corner 142 and/or fourth corner 144may be at a location where the overlapped section 120 intersects with orotherwise approaches the overlapping section 130. The third corner 143may be at a location where one overlapping section 130 intersects withor otherwise approaches another overlapping section 130.

The ribs 102 extending along and forming the boundary 115 of theformliner 100 may therefore include the overlapped or overlappingsections 120, 130. However, the ribs 102 along the boundary 115 need notinclude entirely either an overlapped section 120 or an overlappingsection 130. The ribs 102 forming the boundary 115 may includediscontinuities therealong. Thus, the formliner shown in FIGS. 1-2 ismerely one configuration that is possible, and other suitableconfigurations are within the scope of this disclosure.

The ribs 102 may also include one or more internal sections 108 (e.g.,internal ribs, non-overlap ribs). As shown, the internal sections 108may be portions or segments of the ribs 102 other than those portionsalong the boundary 115 of the formliner 100. The internal sections 108may be portions of the ribs 102 that extend or project farther from thebase 103 than other portions of the ribs 102. For example, the internalsections 108 may project farther from the base 103 than the overlappedsections 120. Further, the overlapping sections 130 may be at a similarheight as the internal sections 108. For example, as shown the internalsections 108 may extend to and interface with the overlapping sections130. Portions of the internal section 108 and portions of theoverlapping sections 130 may thus be at the same height or have the samelength from the base 103. Portions of the internal section 108 andportions of the overlapping sections 130 may thus be at the same heightrelative to the base 103. Further detail of the heights andcross-sections of the various sections 108, 120, 130 of the ribs 102 arediscussed herein, for example with respect to FIGS. 10-13.

The cells 104 may have a perimeter or periphery formed by variousportions or sections of the ribs 102 (e.g., connections or connectingareas/points between the ribs 102 and the cells 104). The perimeter ofthe cells 104 may include as shown the internal section 108, theoverlapped section 120, and/or the overlapping section 130. Further, theperimeter of the cells 104 may include one or more sides that extendalong the boundary 115. For example, the cell 104 adjacent to the thirdcorner 143 includes a perimeter with three sides along the boundary 115.Similarly, the cell 104 adjacent to the first corner 141 includes aperimeter with three sides along the boundary 115. The cell 104 adjacentto the second corner 142 includes a perimeter with two sides along theboundary 115, which may include as shown part of the overlapped section120 and part of the overlapping section 130. Similarly, as shown thecell 104 adjacent to the fourth corner 144 may have a perimeter with twosides along the boundary and part of a third side along the boundary115, which may include as shown portions of the overlapped section 120.

The cells 104 may therefore be formed by various portions or sections ofthe ribs 102 and the base 103. For example, some of the cells 104 may beformed by the overlapped section 120 and the internal section 108 of theribs 102. Further, as shown some of the cells 104 may be formed entirelyby the internal sections 108 of the ribs 102. Further, the cells 104 maybe formed by the overlapping sections 130 and the internal sections 108of the ribs 102. Therefore, various portions and sections of the ribs102 along with the base 103 may form the cells 104.

The cells 104 may also have various shapes and sizes. As shown, thecells 104 may be generally rectangular in shape and of same sizes. Someof the cells 104 may have the various or different sizes and/or shapes.Further, other shapes besides rectangular may be implemented, such assquare, triangular, polygonal, rounded, other shapes, and/orcombinations thereof. Thus, the configuration shown of the cells 104 ismerely one example and many other suitable configurations are possible.

The formliner 100 may include one or more transition zones 107. Asshown, there may be seven transition zones 107. There may be fewer ormore than seven transition zones 107, such as one, two, three, four,five, six, eight, nine, ten, fifteen, twenty, fifty, one hundred, ormore. The transition zones 107 may be a portion or segment of one ormore ribs 102 with transitions between various sections or portions ofthe ribs 102. For example, as shown the transition zones 107 may providea transition between the overlapped sections 120 and the internalsections 108 of the ribs 102. Further, as shown the transition zones 107may be located at or near the boundary 115 of the formliner 100. Thetransition zones 107 may be changes in height or other features of thevarious sections of the ribs 102, as discussed in further detail herein,for example with respect to FIG. 18.

FIGS. 3-4 are bottom perspective views of the formliner 100. FIG. 3 is abottom perspective view from one side of the formliner 100, and FIG. 4is a bottom perspective view from the opposite side of the formliner100. As shown, the bottom side of the formliner 100 may include one ormore bottom surfaces 111 (e.g., web, base, etc.). The bottom surfaces111 may be surfaces of the base 103 that are located opposite from theinterior of the cell 104.

The bottom side of the formliner 100 may include one or more channels orconduits 110. The channels 110 may be spacings, which may be emptyspaces or voids or may be filled with material, in between the variouscells 104. As shown, the channels 110 may be empty spaces on theunderside of the ribs 102. The channels 110 may be formed during themanufacturing process to form ribs 102. The channels 110 may be formedfrom a mold that is used to create the cells 104 of the formliner 100.The mold includes projections in the shape of the cells 104 where theprojections are spaced so that the channels 110 form in the formliner100 in between the cells when produced with the mold. While the channels110 may be spaces in between the cells 104, the channels 110 may befilled with material. Therefore, the channels 110 may be solid portionsof the formliner 100 in between the cells 104. The channels 110 may alsobe spaces or materials within the ribs 102. For example, the ribs 102shown in FIGS. 1-2 may form the channels 110 on the underside (asoriented in FIGS. 1-2) of the ribs 102.

FIG. 5 is a top view of the formliner 100. As shown, the formliner mayinclude various rows or layers of the cells 104 extending from left toright as oriented in the figure. The rows of the cells 104 may bealigned with each other or they may be unaligned. Further, the rows maybe complete or incomplete. Therefore, various configurations of thecells 104 may be implemented.

As mentioned, the cells 104 may have a perimeter that is formed byvarious ribs 102. Further, the cells 104 may define or form a cell spaceor volume 105. As shown, the cell 104 adjacent to the second corner 142,or other cells, may include a cell volume 105 that extends to thesurrounding four ribs 102 of the cell 104. In the cell 104 adjacent tothe third corner 143, the cell volume 105 extends between threeoverlapping sections 130 of the ribs 102 and one internal section 108 ofthe ribs 102. The cell volume 105 is shown in dashed lines, indicatingthat it is merely a geometric reference and not a physical feature ofthe formliner 100. Further, the dashed lines are shown offset from thesurrounding ribs 102 for purposes of clarity. It is understood that thecell volume 105 may extend to the inner surfaces of the surrounding ribs102. The cell volume 105 may therefore have a depth, which is shown andexplained in further detail herein, for example with respect to FIG. 10.Further, while a single cell 104 has been used to describe the cellvolume 105, it is understood that any of the other cells 104 may alsoform or define other cell volumes 105.

Further shown in FIG. 5 is the boundary 115. As mentioned, the boundary115 extends along the outer perimeter of the formliner 100. Further, theboundary 115 may have a variety of contours besides those shown anddescribed elsewhere herein. For instance, in FIG. 5 the segment of theboundary 115 between the first corner 141 and the second corner 142includes inner portions that are aligned with each other and outerportions that are aligned with each other. Similarly, the segment of theboundary 115 between the third corner 143 and the fourth corner 144includes inner portions that are aligned with each other and outerportions that are aligned with each other. These two opposite segmentsof the boundary 115 are therefore complementary such that two of theformliners 100 may be coupled or paired together. Such assemblies arediscussed in further detail herein, for example with respect to FIGS.14-22.

For purposes of the present discussion, it is understood that othercomplementary configurations of opposite segments of the boundary 115may be embodied. The portion of the boundary 115, going in the directionfrom the first corner 141 to the second corner 142, may be locatedprogressively farther inward. Further, the inner portions of thissegment of the boundary 115 need not be aligned with each other but maybe offset or located progressively farther inward or outward, orcombinations thereof, in the direction from the first corner 141 to thesecond corner 142. Similarly, the portion of the boundary 115 extendingfrom the fourth corner 144 to the third corner 143 may have a differentconfiguration than what is shown. In the direction from the fourthcorner 144 to the third corner 143, this segment of the boundary 115 mayinclude outer portions that are located progressively farther outward orinward. Similarly, this segment of the boundary 115 may include innerportions that are aligned or that are located progressively fartheroutward in a direction from the fourth corner 144 to the third corner143. Therefore, a multitude of configurations may be implemented for thevarious segments of the boundary 115.

The formliner 100 may further include cutouts along the boundary 115. Asshown in FIG. 5, the formliner 100 may have a first cutout 151 and asecond cutout 153. The cutouts 151, 153 maybe located at the corners ofthe formliner 100. As shown, the first cutout 151 may be located at thefirst corner 141, and the second cutout 153 may be located at the secondcorner 142. This is merely one example, and there need not be twocutouts. There may be no cutouts. There may only be one cutout. Forexample, there may only be a single cutout 153 at the first corner 141,but no cutout at the second corner 142. The overlapped section 120 maybe formed to extend further, transversely to the overlapping section 130to replace the cutout 153 illustrated in FIG. 5. A transition zone fromthe overlapped section 120 to the overlapping section 130 may bepositioned where the end of the overlapping section 130 is illustratedat cutout 153 in FIG. 5. The overlapping section 130 may be formed toextend further transversely to the overlapped section 120 to replace thecutout 153 illustrated in FIG. 5. A transition zone 107 from theoverlapped section 120 to the overlapping section 130 may be provided,positioned, and/or formed where the end of the overlapped section 120 isillustrated at cutout 153 in FIG. 5.

There may be three or four cutouts. For example, there may be one or twoadditional cutouts besides what are shown in FIG. 5, such as a (third)cutout at the third corner 143 and/or a (fourth) cutout at the fourthcorner 144. The various cutouts may be formed by interfaces of variousportions of the boundary 115. For example as shown, the first cutout 153may be formed by an interface of an overlapped section 120 and anotheroverlapped section 120 at the first corner 141. As shown, the secondcutout 153 may be formed by an interface of the overlapping section 130and the overlapped section 120 at the second corner 142. Therefore, thecutouts may be formed on one side by the end of one portion of theboundary 115 and on the other side by the end of another portion of theboundary 115. For example, as shown the second cutout 153 at the secondcorner 142 is formed on one side by an end of the overlapping section130 and on the other side by an end of the overlapped section 120. Thefirst cutout 153 may be similarly formed at the second corner 142 by anend of the overlapped section 120 and on the other side by an end of theoverlapped section 120. These are merely some examples of possibleconfigurations for the cutouts and others that are suitable may beimplemented.

FIG. 6 is a bottom view of the formliner 100. As shown, the channels 110may connect with each other and form a system or network of the channels110 along the bottom of the formliner 100. The channels 110 may extendtoward an interface with the overlapped sections 120 and/or theoverlapping sections 130. As mentioned, the channels 110 may be featuresof the ribs 102. Thus, the channels 110 may have a layout that resemblesthe general layout of the ribs 102. It is understood that theconfiguration of the channels 110 as shown is merely one example andthat other suitable configurations may be implemented.

FIG. 7 is a detailed view of a portion of the formliner 100 along theline 7-7 as indicated in FIG. 2. FIG. 8 is a detailed view of a portionof the formliner 100 along the line 8-8 as indicated in FIG. 3. FIG. 9is a detailed view of a portion of the formliner 100 along the line 9-9as indicated in FIG. 5. As shown, the formliner 100 can have one or morerib openings 160 in the overlapping sections 130 of the formliner 100.The rib opening 160 can allow the overlapped sections 120 to passtherethrough, thus enabling the overlapping sections 130 to be overlaidonto the overlapped sections 120. The rib openings 160 can be dispersedthroughout an extent of the overlapping sections 130 as illustrated in,for example, FIGS. 2-4. The rib openings 160 can allow overlapping withminimal, minimized, or substantially or relatively no visible seaming ofconnected/assembled formliners by allowing the overlapping portions ofthe formliners to fit tightly and closely against other portions of theformliner such as transition zones 107 and/or internal sections ribs108. For example, the rib openings 160 can be sized and positioned to beoverlaid and mate with protrusion 162 as discussed herein.

As illustrated in FIGS. 1, 2, 5, and 9, the formliner can have one ormore channel(s), canal(s), conduit(s), slit(s), passage(s), vein(s), orgroove(s) 170. The channel(s) 170 may be spacings in between the variouscells 104. As shown, the channel(s) 170 may be empty space(s) betweenbase 103 and the overlapped section 120 of the formliner 100. Thechannel(s) 170 may be formed during the manufacturing process. Thechannel(s) 170 may be formed from a mold that is used to create thecells 104 of the formliner 100. The mold includes indentations in theshape of the channel(s) 170 where the indentations are spaced so thatthe channel(s) 170 forms in the formliner 100 in between the cells 104when produced with the mold. As discussed herein, the channel 170 may besized and positioned to accept a rib edge 241 (FIG. 11) of anoverlapping section 130 when formliners are interconnected.

As illustrated in FIGS. 1, 2, 5, and 9, the channel 170 can extend alongthe peripheries 210 of the base 103. The channel 170 can extend alongthe boundary of the formliner 100 substantially an extent of theoverlapped sections 120 of the formliner 100. The channel 170 can extendbetween the first corner 141 and the second corner 142 along, forexample, the boundary 115 of the formliner 100 between the first corner141 and the second corner 142 and/or along peripheries 210 of the cells104 between the first corner 141 and the second corner 142. As shown inFIG. 9 (and FIG. 5), the channel 170 can be substantially continuous(e.g., without breaks or unbroken) along the boundary 115 between thefirst corner 141 and the second corner 142. Further, as shown in FIG. 5,the channel 170 can be substantially continuous (e.g., without breaks orunbroken) along the boundary 115 between the first corner 141 and thefourth corner 144.

The channel 170 can extend between the first corner 141 and the fourthcorner 144 along, for example, the boundary 115 of the formliner betweenthe first corner 141 and the fourth corner 144 and/or along peripheries210 of the cells 104 between the first corner 141 and the fourth corner144. The channel 170 can be substantially continuous (e.g., withoutbreaks) along boundary 115 between the first corner 141 and the fourthcorner 144.

As shown in FIGS. 7 and 8 by dashed lines corresponding to or along theopenings 160, the formliners 100 may be formed without some or all ofthe openings 160. For example, as discussed herein, a rib edge of theoverlapping section 130 may extend into the channel 170 when theformliners are interconnected or assembled. A continuous rib edge (241,see FIG. 10) of the overlapping section(s) 130 without openings 160 mayextend along and in a substantially continuous channel 170 between thefirst corner 141 and the second corner 142 and/or the first corner 141and the fourth corner 144.

The channel 170 may have breaks, bumps, projections, or protrusions 162corresponding to openings 160 in the formliner 100. The channel 170 mayhave breaks (e.g., protrusions 162) corresponding to ribs 102 (e.g.,internal ribs 108) as discussed herein. The channel 170 may be notwholly continuous between the first corner 141 and the second corner 142and/or the first corner and the fourth corner 144. For example,protrusions 162 may be positioned in the channel 170 corresponding towhere the internal sections 108 of the ribs 102 extend or project intoor toward the overlapped sections 120 with, for example, transitionzones 107 connecting internal section 108 and the overlapped sections120. Accordingly, the openings 160 may be positioned over or onto theprotrusions 162 when the formliners are interconnected or assembled.

FIG. 10 is a cross-section view of a portion of the formliner 100 astaken along the line 10-10 as indicated in FIG. 5. As shown in FIG. 10,the cell 104 may be bounded on two sides by the boundary 115 (and/orperimeter 210 as discussed herein). On one side of the cell 104, theboundary 115 may include an overlapped section 120. The opposite side ofthe cell 104 may also include an overlapped section 120. It isunderstood that one or both of the portions of the boundary 115 shown inFIG. 10 may be overlapping sections 130, as discussed in further detailherein for example with respect to FIG. 11. It is further understoodthat the overlapped sections 120 and the overlapping sections 130 aresections or segments of the ribs 102. Therefore, the ribs 102 may haveeither an overlapped section 120 or they may be shaped like theoverlapping section 130. Thus, the boundary 115 may include the ribs 102as either the overlapped sections 120 and/or the overlapping sections130.

Each of the sections 120, 130 may be formed from one or more walls orsegments. As shown in FIG. 10, the formliner can include a channel 170connected to the base 103. The channel 170 can accept and mate with arib edge (241) as discussed herein and in particular, in reference toFIGS. 14-18. The channel 170 can extend toward a support surface (of aframework 602, see FIG. 22) discussed herein relative to the base 103.It is understood that while the base 103 is shown to be generally flator planar in configuration, the base 103 can be formed to accommodateany desired pattern. For example, the base 103 can be formed to includea textured pattern (e.g., decorative pattern 402) having a masonrydesign or other designs as discussed herein. The design can have anamplitude as discussed herein that extends toward and/or contacts thesupport surface (of a framework 602, see FIG. 22).

As shown in FIG. 10, the overlapped section 120 may include a first wall204. The first wall 204 may be connected to and extend away from thechannel 170 (e.g., generally perpendicular to the base 103). The firstwall 204 may be directly connected to channel 170. As shown, the firstwall 204, the channel 170, and/or the base 103 may be integral such thatthey are formed from the same monolithic piece of material. The firstwall 204 may be attached to channel 170 and/or the base 103 with varioussuitable mechanical attachments, such as nails, rivets, adhesive, tape,string, or other suitable means.

The first wall 204 may include a lower region or lower portion 212(e.g., an inner portion 212 relative to the straight portion 208). Thelower portion 212 of the first wall 204 may be on a side of the firstwall 204 that is opposite the cell 104. The lower portion 212 may referto an area or region of intersection of the first wall 204 and the base103. The intersection of the base 103 and the lower portion 212 (and inparticular, the angled portion 206 of the first wall 204) can form theperimeter or periphery of the cell 104 as discussed herein, such as, forexample perimeter 210 in reference to FIGS. 2 and 11.

The lower portion 212 may be formed by the intersection of the firstwall 204 and a bottom or exterior surface 211 of the channel 170. Thisintersection may be a sharp point as shown, or it may be rounded, othershapes, or combinations thereof. Further, the lower portion 212 mayinclude more than just the point or intersection of the first wall 204and the bottom surface 211. For instance, the lower portion 212 mayextend along the first wall 204 for a distance toward a second wall 220of the overlapped section 120. Therefore, the lower portion 212 can bethe lowest area of the outside surface of the first wall 204, but mayinclude other portions of the first wall 204 there above. The lowerportion 212 may extend from the first end of the first wall 204 to alocation halfway along the first wall 204. Thus, first wall 204 may havea length or height H1′ (e.g., corresponding to depth H1″ of the channel170) approximately equal to half the length or height H1. The first wall204 may have other suitable lengths H1′ as discussed herein, such asabout ¼, ⅓, ⅔, or ¾ the length of H1, including the foregoing values andranges bordering therein. The length H1′ may be the length from anexterior or top surface of the second wall 220 (e.g., surface of thesecond wall 220 configured to be overlapped by the overlapping section130) and an interior surface of the channel 170 (e.g., surfaceconfigured to be adjacent or face the rib edge 241 of the overlappingsection 130).

The overlapped section 120 may further include a second wall 220. Thesecond wall 220 may be connected to the first wall 204. The first wall204 may be connected to the base 103 and/or channel 170 on one end ofthe first wall 204 and on the opposite end may be connected to thesecond wall 220. As shown, the second wall 220 may connect with an endof the straight portion 208 of the first wall 204. The second wall 220may be integral with the first wall 204 such that they are made from thesame monolithic piece of material. The second wall 220 may bemechanically attached to the first wall 204 in a variety of manners,including those described above with respect to the first wall 204 andthe base 103, as well as others.

As shown, the second wall 220 may extend generally outward or away fromthe cell 104 (e.g., generally parallel with the base 103). The directionof extension of the second wall 220 may be generally perpendicular tothe general direction of extension of the first wall 204. The secondwall 220 may also extend in any direction that is substantially parallelwith the base 103. However, these are merely some examples and a varietyof configurations of the second wall 220 may be implemented. The secondwall 220 may not be generally perpendicular to the first wall 204 orgenerally parallel with the base 103. For instance, the second wall 220may extend generally away from the cell 104 and downward as oriented inFIG. 10.

The overlapped section 120 may further include a third wall 224. Thesecond wall 220 may be further connected to a third wall 224. The thirdwall 224 may be connected to the second wall 220 and extend in adirection away from the second wall 220 as shown. The third wall 224 maybe integral with the second wall 220 such that they are formed from thesame monolithic piece of material. The third wall 224 may be connectedor coupled with the second wall 220 in the same or similar mannerdescribed with respect to the connection between the second wall 220 andthe first wall 204 of FIG. 10.

The third wall 224 may include a rib edge 221 (e.g., free end, secondrib edge, rib end, second rib end). The rib edge 221 of the third wall224 may be on an end of the third wall 224 opposite that of the end thatis connected with the second wall 220. The rib edge 221 may therefore bean edge of the overlapped section 120 and thus an edge of the ribs 102.The rib edge 221 may have a projection or curve 225 connected to the ribedge 221. The projection 225 may rest against a support surface asdiscussed herein. As shown, the third wall 224 may extend past the base103 or bottom surface 111 of the cell 104. The third wall 224 may extendin a generally downward direction as oriented in the figure such thatthe rib edge 221 is in a same or similar plane as the base 103 or bottomsurface 111 of the cell 104. The rib edge 221 may be generally flat. Therib edge 221 may have other shapes, such as pointed, rounded, segmented,other shapes or contours, or combinations thereof.

The overlapped section 120 may have a variety of sizes and dimensions.As shown, the overlapped section 120 may have a height equivalent to thedimension H1 as shown in FIG. 10 between an exterior or top surface ofthe second wall 220 (e.g., surface configured to be overlapped by theoverlapping section 130) and the rib edge 221 (e.g., surface of the ribedge 221 configured to rest against a support surface as discussedherein).

As further shown, the overlapped section 120 may have a width or lengthequivalent to the dimension W1 as indicated in FIG. 10. The dimension W1may be between exterior surfaces of the first wall 204 and the thirdwall 224 (e.g., surfaces of the first wall 204 and the third wall 224configured to be overlapped by the overlapping section 130).

As mentioned, the cells 104 may define a cell volume 105. As shown inFIG. 10, the cell volume 105 may extend from the base 103 to a top edgeof the overlapped section 120. The cell volume 105 may extend from thebase 103, over or into the channel 170, to the second wall 220. Further,the cell volume 105 may extend from one first wall 204 to an oppositefirst wall 204, as shown. The cell volume 105 may therefore have anouter contour that matches the inner surfaces defining the cell 104. Forexample, the cell volume 105 may be bounded by the first wall 204, aswell as by the base 103. Further, as mentioned, the cell volume 105 isshown in dashed lines because it is a geometric reference as opposed toa physical feature of the formliner 100. The dashed lines indicating theboundary of the cell volume 105 are slightly offset from the variousbounding features of the cell 104 for purposes of clarity, however it isunderstood that the cell volume may extend to and contact these variousfeatures, as described herein.

The overlapped section 120 may define or otherwise form a first space222. As shown, the first space 222 may be bounded on three sides by theoverlapped section 120. The first space 222 may be empty space as shown.The first space 222 may be filled, either partially or entirely, withmaterial. The overlapped section may include a solid first space 222with the first wall 205, the second wall 230, and the third wall 224being outer surfaces of the first space 222. As illustrated, the firstwall 204, the second wall 220, and the third wall 224 may form agenerally C-shaped cross-sectional profile (e.g., C section) at leastpartially bounding the first space 222. The generally C-shapedcross-sectional profile can be rounded (e.g., horse-shoe shaped) or witha square/rectangular configuration as illustrated in FIG. 10.

FIG. 11 is a cross-section view of a portion of the formliner as takenalong the line 11-11 as indicated in FIG. 5. As shown in FIG. 11, thecell 104 may be bounded on opposite sides by the perimeter 210 and/orthe boundary 115, where the boundary 115 includes the overlappingsections 130. The overlapping sections 130 may include a first wall 205(e.g., a fourth wall) connected to and extending away from the base 103as shown. The first wall 205 of the overlapping section 130 may havesimilar features and functionalities as the first wall 204 of theoverlapped section 120 described herein.

The overlapping sections 130 may include a second wall 230 (e.g., afifth wall). The first wall 205 may connect with the second wall 230.The second wall 230 may have similar features and functionalities as thesecond wall 220 of the overlapped section 120. For example, the secondwall 230 may extend generally outward or away from the cell 104 (e.g.,generally parallel with the base 103). The direction of extension of thesecond wall 230 may be generally perpendicular to the general directionof extension of the first wall 205. The second wall 230 may also extendin any direction that is substantially parallel with the base 103.

The overlapping sections 130 may include a third wall 240. The secondwall 230 may connect with third wall 240. The second wall 230 may havesimilar features and functionalities as the second wall 220 of theoverlapped section 120. The third wall 240 may be connected to thesecond wall 230 and extend in a direction away from the second wall 230as shown. The third wall 240 may be integral with the second wall 230such that they are formed from the same monolithic piece of material.The third wall 240 may be connected or coupled with the second wall 230in the same or similar manner described with respect to the connectionbetween the second wall 220 and the first wall 204 of FIG. 10.

As further shown in FIG. 11, the third wall 240 may have a rib edge 241(e.g., free end, first rib edge, rib end, first rib end). The rib edge241 of the third wall 240 may be on an end of the third wall 240 that isopposite that of the end that is connected to the second wall 230. Asshown, the third wall 240 may extend past or beyond the base 103 orbottom surface 111 of the cell 104. The third wall 240 may extend in agenerally downward direction as oriented in the figure such that the ribedge 241 is in a same or similar plane as the base 103 or bottom surface111 of the cell 104. The third wall 240 may extend in a directiongenerally parallel to the first wall 205, generally perpendicular to thesecond wall 230, and/or generally perpendicular to the base 103 orbottom surface 111.

Each of the walls of the ribs 102 can have an extent, length, dimensionalong the cross-sectional profiles illustrated in, for example, FIGS. 10and 11. Where the extents of the wall of the ribs 102 connect can formedges or corners of the ribs 102 or walls. For example, the connectionof the first wall 204 to the second wall 220 can form an edge or corneras illustrated in, for example, FIG. 10. The second wall 220 connectingto the third wall 224 can form an edge or corner as illustrated in, forexample, FIG. 10. The connection of the first wall 205 to the secondwall 230 can form an edge or corner as illustrated in, for example, FIG.11. The second wall 230 connecting to the third wall 240 can form anedge or corner as illustrated in, for example, FIG. 11. The dimension orlength between the edges or corners can be an extent of the walls asdiscussed herein. The extents can be perpendicular to a correspondingextent where the walls connect.

Similar to the cell 104 as described in FIG. 10, the cell 104 shown inFIG. 11 may also be bounded by the side of the first wall 205 that facesthe cell 104. Thus the first wall 205 may extend around the boundary ofthe cell 104, such that a portion of the first wall 205 is visible inbetween the two cross-sections of the overlapping sections 130 asoriented in FIG. 11.

As further shown in FIG. 11, the cell 104 may include a perimeter,boundary or perimeter 210 (e.g., an inner perimeter, boundary, orperiphery). As shown, the perimeter 210 may be formed by the interfaceof the base 103 with the first wall 205. The perimeter 210 may be avertex formed by the intersection of the base 103 and the first wall205. The perimeter 210 may therefore be inside the cell 104. Theperimeter 210 may not be a sharp corner but may be rounded instead. Theperimeter 210 may be a sharp corner in some locations along theperimeter 210 of the cell 104 and it may be rounded or other shapes atother portions of the perimeter 210 of the cell 104. Further, theperimeter 210 may generally extend beyond the intersection of the firstwall 205 and the base 103 within, for example, the cell volume 105. Theperimeter 210 may have contours and shapes that follow along a texturedpattern that may formed in the base 103 as discussed herein. Forexample, the perimeter 210 may be not a straight line along theintersection of the base 103 and the first wall 205.

Further shown in FIG. 11 is the cell volume 105. The cell volume 105 mayhave any of the features and functionalities as described herein.Further, the cell volume 105 may be defined by the various features ofthe cell 104 as described with respect to FIG. 11. For example, the cellvolume 105 may be defined by the first wall 205, the base 103, theperimeter 210, and/or other features.

The overlapping section 130 may have a variety of sizes and dimensions.Further, because the overlapping section 130 of one formliner may beassembled with the overlapped section 120 of another formliner, thevarious dimensions of these sections may be sized to facilitate suchoverlapping. That is, the overlapping section 130 of a second formliner100 may overlay onto the overlapped section 120 of a first formliner100. Therefore, the second wall 230 of the overlapping section 130 of asecond formliner 100 may rest on the second wall 220 of the overlappedsection of a first formliner 100. Similarly, the outer surface of thefirst wall 204 of the overlapped section 120 of a first formliner 100may abut or otherwise contact the third wall 240 of the overlappingsection 130 of a second formliner 100. As indicated in FIG. 11, thesecond wall 230 may have a length or width equivalent to the dimensionW2, and the third wall 240 may have a length or height equivalent to thedimension H2 based on inner surfaces of the second and third walls 230,240 (e.g., surfaces facing the second space 242).

The overlapping section 130 may define or form a second space 242. Asshown and as oriented in FIG. 11, the second space 242 may be defined bythe area underneath the second wall 230, on the side of the first wall205 that is opposite from the cell 104, and enclosed by the third wall240. As shown, the second space 242 may have a length or widthequivalent to the dimension W2 as indicated. W1 and W2 can be about ¼inches. W1 and W2 can be about 1/16 to about 1.5 inches, including about⅛ to about 1 inches, including about ¼ to about ½ inches, including theforegoing values and ranges bordering therein. As further shown, thesecond space 242 may have a length or height equivalent to the dimensionH2. H2 may substantially correspond and/or be substantially a same orsimilar length or extent as H1′.

As illustrated, the first wall 205, the second wall 230, and the thirdwall 240 may form a generally C-shaped cross-sectional profile (e.g., Csection) at least partially bounding the second space 242. The generallyC-shaped cross-sectional profile can be rounded (e.g., horse-shoeshaped) or with a square/rectangular configuration as illustrated inFIG. 11. The second space 242 defined by the overlapping section 130 ofthe formliner 100 may be configured to receive a portion of theoverlapped section 120 of another formliner, as discussed in furtherdetail herein, for example with respect to FIGS. 16-17.

As discussed in further detail herein, for example with respect to FIGS.16-17, the overlapping section 130 may overlay onto the overlappedsection 120. Therefore, the dimension W1 shown in FIG. 10 may besubstantially equivalent to the dimension W2 in FIG. 11. Thus, thelength of the second wall 220 of the overlapped section 120 that extendsbeyond the first wall 204 may be substantially equivalent to the lengthof the second wall 230 of the overlapping section 130. Similarly, thelength of the first space 222 as indicated by the dimension H1 may besubstantially equivalent to the length of the third wall 240 of theoverlapping section 130 indicated by the dimension H2. W1 can beequivalent to W2. However, there may be some reasonable deviationbetween W1 and W2. W1 may be slightly less than W2, for example toaccommodate manufacturing tolerances. Similarly, H1 may be equivalent toH2. However, some reasonable deviation between H1 and H2 may beimplemented. H1 may be slightly larger than H2, for example toaccommodate for manufacturing tolerances. These are just some of thepossible relationships between the dimensions and others are possible.

FIG. 12 is a cross-section view of a portion of the formliner 100 astaken along the line 12-12 as indicated in FIG. 5. As shown, theoverlapped section 120 may include a top surface 250 that is lower thana top surface 260 of the internal section 108. As shown, the top surface250 may be connected to the top surface 260 by a channel 170. Thechannel 170 may therefore connect the top surface 250 of the overlappedsection 120 to the top surface 260 of the internal section 108.

FIG. 13 is a cross-section view of a portion of the formliner 100 astaken along the line 13-13 as indicated in FIG. 6. As shown, two cells104 may be on either side of the conduit 110. The conduit 110 may beformed or defined by the walls 215 that are in between the conduit 110and the two adjacent cells 104. The walls 215 may have similar featuresand/or functionalities as the first wall 204 and/or the first wall 205described, for example, with respect to FIGS. 10 and 11. The walls 215need not have various angled or straight portions. The walls 215 may bea single segment. For example, the walls 215 may be one angled portion,one straight portion, or other suitable configurations.

The wall 215 may be connected to or otherwise coupled with the base 103.As shown, the angled portion 216 of the wall 215 may be connected to orotherwise coupled with the base 103. The wall 215 and the correspondingbase 103 to which the wall 215 is coupled may be formed from the samecontinuous monolithic piece of material. The wall 215 may be a separatepiece that is mechanically connected with the base 103.

The walls 215 of the two adjacent cells 104 may be connected by a bridge218 (e.g., similar to second walls 220, 230). The bridge 218 may beconnected to or otherwise coupled with the walls 215. As shown, thebridge 218 may be connected to or otherwise coupled with the straightportion 217 of the walls 215. Therefore, the conduit 110 may be definedby the walls 215 and the bridge 218. The conduit 110 is shown as a spacedefined by the various structures. The conduit 110 may be filled inpartially or entirely with material, as mentioned. Therefore, the walls215 and/or the bridge 218 may be surfaces of the conduit 110. Forexample, the conduit 110 may be a solid piece of material wherein theside surfaces of the conduit 110 may form the wall 215 and the end ofthe conduit 110 may form the bridge 218.

FIG. 14 is a top perspective view of an assembly 300 of variousformliners, and FIG. 15 is a bottom perspective view of the assembly300. As shown, the assembly 300 may include a (first) formliner 100A, a(second, at least one other, third) formliner 100B, a (fourth) formliner100C and a (second, at least one other, third) formliner 100D. Theseformliners may be the same or similar as the formliner 100 describedherein. Therefore, although different designations maybe given to thevarious formliners shown in the assembly 300, it is understood that thefour formliners 100A, 100B, 100C, 100D may all be the same formliner. Inthis manner, multiple formliners with the same configurations may beassembled together. Further, the assembly 300 is merely one example, andthe formliners may be assembled in other configurations. Two, three,five, six, ten, fifteen, fifty or more formliners may be assembledtogether.

As shown, the four formliners 100A, 100B, 100C, 100D may be assembled ina 2×2 assembly. That is, the assembly 300 may include two formliners100A, 100B aligned next to two other formliners 100C, 100D that may besimilarly aligned. The four assembled formliners 100A, 100B, 100C, 100Das shown may have similar features and functionalities as the formliner100 described above. For example, the formliner 100A may have a firstcorner 141A, a second corner 142A, a third corner 143A, and a fourthcorner 144A. Similarly, the formliner 100B may have a first corner 141B,a second corner 142B, a third corner 143B and a fourth corner 144B.Similarly, the formliner 100C may have a first corner 141C, a secondcorner 142C, a third corner 143C, and a fourth corner 144C. Similarly,the formliner 100D may have a first corner 141D, a second corner 142D, athird corner 143D, and a fourth corner 144D. The various corners may besimilar to the corners of the formliner 100 described herein. Thus forexample referring to formliner 100A, the first corner 141A may besimilar to the first corner 141 of the formliner 100, the second corner142A may be similar to the second corner 142 of the formliner 100, thethird corner 143A may be similar to the third corner 143 of theformliner 100, and the fourth corner 144A may be similar to the fourthcorner 144 of the formliner 100. The respective corners of the otherthree formliners 100B, 100C, 100D in the assembly 300 may also have thesame features and/or functionalities as the respective corners of theformliner 100.

As shown, the formliners 100A, 100B, 100C, 100D may be assembled bybringing together various complementary portions of the boundaries ofthe formliners. Thus, the first corner 141A of the formliner 100A maycontact, interface with, abut, join, assemble with, meet, or otherwisebe adjacent to the fourth corner 144D of the formliner 100D. The secondcorner 142B of the formliner 100B may be adjacent to the third corner143C of the formliner 100C. These junctures of the formliners in theassembly 300 may be generally on the interior of the assembly 300.However, there may be junctures along or near the outer perimeter of theassembly 300. As shown, the first corner 141B of the formliner 100B maybe adjacent to the fourth corner 144C of the formliner 100C. The secondcorner 142A of the formliner 100A may be adjacent to the third corner143D of the formliner 100D. The fourth corner 144A of the formliner 100Amay be near the third corner 143B of the formliner 100B. The firstcorner 141D of the formliner 100D may be near the second corner 142C ofthe formliner 100C.

The order of assembly of the formliner 100A, 100B, 100C, 100D may be asfollows. The first formliner positioned for assembly may be formliner100D. Next, the overlapping sections 130 of either formliner 100A orformliner 100C can be overlaid onto the overlapped sections 120 offormliner 100D. For example, formliner 100A can be laid down as thefirst formliner, and formliner 100B can be laid down as the secondformliner assembled. The formliner 100D can be laid down as the third(at least one other) formliner assembled, and the formliner 100C can belaid down as the fourth formliner assembled. As another example,formliner 100A can be laid down as the first formliner, and formliner100D can be laid down as the second formliner assembled. The formliner100B can be laid down as the third (at least one other) formlinerassembled, and the formliner 100C can be laid down as the fourthformliner assembled. Any of the formliner 100A, 100B, 100C, 100D can belaid down simultaneously to interconnect as discussed herein. Whencontinuing to assemble five or more formliners, assembled formliner 100Ccan be considered the first formliner (e.g., as formliner 100A was whenconnecting the first four formliners) to connect with additionalformliner in one or more orders discussed above.

The formliners may also contact each other (e.g., connect, assemble,overlay) along the boundaries 115 of the formliners. As shown, theformliner 100B may contact the formliner 100C along an interface fromthe juncture of the second corner 142B and the third corner 143C, andextending to the juncture of the first corner 141B and the fourth corner144C. Similarly, the formliner 100A may contact the formliner 100D alongan interface extending from the juncture of the second corner 142A andthe third corner 143D to the juncture of the first corner 141A and thefourth corner 144D, and similarly for other corresponding corners of theformliners (e.g., 144A and 143B as well as 142C and 141D). Along theseinterfaces, the various transition zones of the formliners may contactthe overlapping sections of adjacent formliners. The overlapping section130D of the formliner 100D may contact in various locations thechannel(s) 170A and/or transition zones 107A of the formliner 100A.Similarly, the overlapping section 130C of the formliner 100C maycontact various channels 170B and/or transition zones 107B of theformliner 100B. A cross-section view of one such interface as takenalong the line 18-18 as indicated in FIG. 14 is shown in FIG. 18.Similar interface may exist between the formliner 100A and the formliner100D and/or the other interconnecting formliners.

The various formliners may further have interfaces along other sides ofthe boundaries of the formliners. As shown in FIG. 18, the formliner100B may contact the formliner 100C along an interface that extends fromthe second corner 142B to the fourth corner 144C. Similarly, theformliner 100A may contact the formliner 100B along an interface thatextends from the first corner 141A to the third corner 143B. Theseinterfaces may be generally straight as shown, however otherconfigurations may be implemented. Further, along these interfaces theformliners may contact the transition zones of adjacent formliners.

FIGS. 16-18 show various cross-section views as taken along respectivelines as indicated in FIG. 14. FIG. 16 is a cross-section view of aportion of the assembly 300 as taken along the line 16-16. FIG. 17 is across-section view of a portion of the assembly 300 as taken along theline 17-17. FIG. 18 is a cross-section view of a portion of the assembly300 as taken a long line 18-18. FIG. 19 is a cross-section view of aportion of an other assembly 300 as taken a long line 18-18. While FIGS.16 and 17 show the rib system 112 substantially forming a raked jointand FIGS. 18 and 19 show the rib system 112 substantially forming aflush joint, it is understood that the features, functionalities, andconcepts of the rib system 112 discussed herein can be applied to tooljoints, vee joints, concave joints, ironed joints, extruded joints,beaded joints, struck joints, weathered joints, squeezed or weepingjoints, grapevine joints, and/or other suitable joints used in curablematerial designs.

Referring to FIG. 16, a portion of the assembly 300 is shown where theformliner 100B interfaces with the formliner 100C. As shown, theoverlapping section 130C overlaps the overlapped section 120B. Thisoverlapped section 120B may be similar to the overlapped section 120described herein. This overlapping section 130C may be similar to theoverlapping section 130 described herein. The overlapped section 120Bmay include the first wall 204 coupled with the second wall 220, and thesecond wall 220 coupled with the third wall 224. Therefore, as shown theoverlapping section 130C may include the first wall 205 coupled with thesecond wall 230, and the second wall 230 coupled with the third wall240. Further, the third wall 224 may have the rib edge 221, the thirdwall 240 may have the rib edge 241.

As shown, the overlapping section 130C at least partially abuts andpartially rests upon the overlapped section 120B. The two formliners100B and 100C may be brought into contact with each other in a varietyof ways. For example, the formliners 100B and 100C may be manuallybrought into contact with each other by a user, a machine may place themin the shown configuration, other processes may be used, and/or comecombinations thereof. As shown, the third wall 240 may contact the firstwall 204. The third wall 240 may abut the first wall 204. There may beno void or space in between the third wall 240 and the first wall 204such that the respective surfaces completely/directly contact eachother. The third wall 240 may partially contact the first wall 204.

As shown in FIG. 16, the assembled formliners 100B, 100C may include thethird wall 240 contacting or otherwise being located near or adjacent tothe first wall 204. The third wall 240 may contact or otherwise be nearthe lower portion 212. The rib edge 241 may contact or otherwise be nearthe first wall 204. The rib edge 241 may contact or otherwise be near oradjacent to the base 103. The rib edge 241 may be coplanar orcoextensive (e.g., end) with the bottom surface 111 of the cell 104 ofthe formliner 100B. Therefore, a variety of configurations between thethird wall 240 and the first wall 204 may be implemented.

The assembled formliners 100B, 100C may include the second wall 230contacting or otherwise being adjacent to the second wall 220. As shown,the second wall 230 may substantially contact the second wall 220.However, similar to the interface between the third wall 224 and thefirst wall 205, the second walls 220, 230 need not entirely contact oneanother. The second wall 220 may partially contact the second wall 230.The second wall 220 may be near or otherwise adjacent to the second wall230. As shown, the second wall 230 may extend such that it issubstantially coextensive with the first wall 205 (e.g., end at or onend of the first wall 205 or where the first wall 205 and the secondwall 230 are connected, such as, for example where the first wall 205and the second wall 230 form a corner). The rib edge 241 may thereforebe coextensive with an edge or surface of the first wall 205. The ribedge 241 of the third wall 240 may be coextensive with a straightportion of the first wall 205. As shown in FIG. 16 (and FIG. 17), theoverlapping section 130C (e.g., first, second, and third walls 205, 230,240) can be overlaid to extend about half of an overall length theoverlapped section 120B (e.g., the first, second, and third walls 204,220, 224). In particular, the combined length of the first, second, andthird walls 205, 230, 240 of the overlapping section 130C can extendabout half the combined length the first, second, and third walls 204,220, 224 of the overlapped section 120C.

The formliners 100B, 100C may include the cell volume 105 defined by thecell 104 and the base 103. As shown, the cell volume 105 may be a spacedefined or otherwise formed by the perimeter of the cell 104. As shown,the formliner 100C (e.g., overlapping section 130C and in particular,the third wall 240) may extend adjacent to the cell volume 105 and enterthe cell volume 105 of formliner 100B. The third wall 240 of theoverlapping section 130C may extend close to or adjacent to the cellvolume 105 and/or extend into the cell volume 105 (e.g., contact orextend downwardly into the cell 104 or cell volume 105 toward theperimeter 210 of the formliner 100B, such as for example, into thechannel 170). The second wall 230 of the overlapping section 130C mayextend close to or adjacent to the cell volume 105 and/or extend intothe cell volume 105 (e.g., contact or extend horizontally into the cell104 or cell volume 105 depending on where the second wall 230 and thethird wall 240 are connected/divided).

As discussed herein, the perimeter 210 may be not a straight line, buthave an outline or contour that generally follows a textured pattern ordecorative pattern 402 of or in a base 103 as discussed herein (e.g.,where the first wall 205 and the base 103 connect or where the channel170 and the base 103 connect). The decorative pattern 402 is illustratedby dashed lines. The dashed lines can represent an extent or path of atop exterior surface 117 of the base 103 along the decorative pattern402 (the top exterior surface 117 of the base 103 configured to face thecurable material). The decorative pattern 402 illustrated by dashedlines is just one example of a possible pattern. Many other patternscorresponding to desired surface patterns as discussed herein may beused. The decorative pattern 402 can be formed by any suitablemanufacturing process as discussed herein. For example the formliner 100may be heated (e.g., in an oven) and vacuum pulled against a form ormold comprising or having the decorative pattern 402. In the process offorming the formliners 100 (including cells 104, ribs 102, etc.) thebase 103 can be vacuum pulled against a portion of the mold having thedecorative pattern 402.

For illustration and discussion purposes, a support surface 406 is shownin FIGS. 16 and 17. The bottom surface 111 and/or third wall 224 (e.g.,rib edge 221) may wholly, partially, substantially contact, abut, comeagainst a support surface 406. The support surface 406 can be orcorrespond to the platform 606 as discussed herein, and in particular,in reference to FIG. 22. The support surface 406 may be the ground,floor, or other substantially flat or planar surface (e.g., a tabletop)against which a formliner rests in a desired position. Such contactsagainst a support surface 406 can provide support, structural integrity(substantial resistance to deformation given a desired curablematerial), and weight bearing capabilities to the respective formliners100 and/or boundaries 115 as discussed herein. As shown, the decorativepattern 402 can vary such that some portions or parts of the bottomsurface 111 may contact the support surface 406 with other portions ofthe bottom surface 111 not contacting the support surface 406 where thebase 103 (and correspondingly the bottom surface 111) has a texturedpattern as discussed herein.

Depending on for example, the decorative pattern 402, the perimeter 210can have a changing or substantially random contour, line, or edgefollowing the outline of the decorative pattern 402 formed in the base103. The decorative pattern 402 can have an amplitude A1 substantiallycorresponding to an extent of the decorative parent pattern 402 at theperimeter 210 (or boundary 115) of the cell 104. The amplitude A1 cancorrespond or be substantially similar or equal to the height H1″ of thechannel 170 as discussed herein. The amplitude A1 can be smaller orshorter relative to the height H1″. The amplitude A1 can substantiallycorrespond to, be the same or similar to, and extend from a top exteriorsurface 117 of the base 103 configured to face curable material to a topinterior surface of the channel 170 (e.g., surface of the channelfacing, adjacent, and/or contacting the rib edge 241 and opposite abottom exterior surface of the channel 170 configured to face a supportsurface 406 as discussed herein).

As shown, the height H1″ of the channel 170 can substantially correspondto the amplitude A1 of the decorative pattern 402 at the perimeter 210of the cell 104. Stated differently, the decorative pattern 402 canextend toward the support surface 406 an extent (A1) substantially equalan extent of the channel 170 (H1″). In such implementations, the channel170 may substantially not be present, provided, or formed relative tothe base 103. For example, a top exterior surface 117 of the base 103configured to face the curable material may be substantially at a samelevel or substantially along a same plane as a top interior surface ofthe channel 170 configured to face the rib edge 241. Accordingly, thechannel 170 may substantially have no depth or extension height orlength relative to the top exterior surface 117 of the base 103 at theperimeter 210 of the cell 104.

The decorative pattern 402 can extend toward the support surface 406 atthe perimeter 210 less than an extent of amplitude A1 that is shown inFIGS. 16 and 17 (e.g., less than an extent of the channel 170 (H1″)).The decorative pattern 402 relative to a level or plane of the base 103may not have an extent or amplitude at the perimeter 210. Accordingly,the decorative pattern 402 may have an extent or an amplitude ofsubstantially zero at the perimeter 210 of the cell 104. Such an extentor amplitude of zero can correspond substantially to a level of the topexterior surface 117 of the base 103 as illustrated in FIGS. 16 and 17.

As shown in FIGS. 16 and 17, the decorative pattern 402 can have avariance in pattern extending to the support surface 406 at a maximumextent or maximum amplitude A2. At amplitude A2 of the decorativepattern 402, the base 103 can extend toward the support surface 406 suchthat the bottom surface 111 of the base 103 contacts the support surface406 to, for example, provide rigidity and structural integrity to thecell 104, rib system 112 (e.g., ribs 102), and/or formliner 100.

For additional support, the rib edge 221 of the overlapped section 120Bcan extend toward the support surface 406 at, for example length orheight H1. The rib edge 221 can contact the support surface 406. Whenthe formliners are assembled and placed against a support surface 406,the rib edge 221 can provide structural support to the rib system 112and/or cells 104. For example, when the overlapping section 130C isoverlaid onto the overlapped section 120B, the rib edge 221 can providerigidity and structural integrity to the overlapped section 120B whilein turn providing rigidity and structural integrity to the overlappingsection 130C.

As discussed herein, the channel 170 can have a length or height H1″that is less than the length or height H1 or H1′. As shown, a bottomsurface of the channel 170 configured to face the support surface doesnot extend to or contact the support surface 406. It is understood thatin certain implementations, length H1″ of the channel 170 may besubstantially equal or have a same extent as length H1 of the third wall224. Accordingly, the formliner 100 may be formed such that the channel170 (e.g., bottom surface) contacts the support surface 406 for furtherrigidity and structural integrity.

The length or height H1″ of the channel 170 can be determined anddesigned based on various variables and inputs depending on the desiredformliner 100. For example, the variables may include desired orpredetermined thickness T1 (FIG. 17) of the formliner 100. The desiredthickness T1 may be determined based on the desired reusability of theformliner 100. For example, if multiple uses of the formliner 100 aredesired, the thickness T1 may be made greater or larger. A single useformliner 100 may have a relatively shorter thickness T1. The thicknessT1 may be substantially uniform or have a same thickness throughout theformliner 100 in, for example, the cell 104 (e.g., base 103 (includingdecorative pattern 402)), rib system 112, including the channel 170. Insome implementations, the thickness T1 may vary depending on the desiredcharacteristics and/or manufacture of the formliner 100. The variablesmay include the desired or predetermined decorative pattern 402, such asfor example, amplitudes A1 and A2. Relatively longer or largeramplitudes A1 and A2 of the decorative pattern 402 may result inrelatively longer or larger heights H1″ of the channel 170, which mayincrease desired thickness T1 of the formliner 100. The variables mayinclude a desired or predetermined length or height H1 of the third wall224. Relatively longer or larger height H1 of the third wall 224 mayresult in relatively longer or larger heights H1″ of the channel 170and/or relatively longer or larger amplitudes A1 and A2 of thedecorative pattern 402, which may increase desired thickness Ti of theformliner 100.

A consideration during formation/manufacture of the formliner may be theresulting thickness T1 of the formliner 100 in various sections of theformliner 100 after vacuum pulling the formliner 100 onto the mold(e.g., vacuum formation process that thins the formliner material froman initial thickness to a thickness T1 as discussed herein). Forexample, if the section of the formliner 100 corresponding to thechannel 170 is pulled too deeply or too much (H1″ is relatively longsuch as approaching the length of H1) where the formliner material isstretched too thinly, the formliner 100 may have undesirablecharacteristics (e.g., bubbling or other manufacturing defects) at, forexample, the channel 170 after manufacture. Accordingly, the depth orlength H1″ of the channel 170 may be reduced or shortened (e.g.,designed to be shallower, including not contacting the support surface406) to mitigate or substantially prevent the undesirablecharacteristics.

On the other hand, if the decorative pattern 402 has a relatively longor large amplitude A1 at the perimeter 210 of the cell 104, the lengthH1″ of the channel 170 may be increased to accommodate the relativelylonger amplitude A1. The larger or longer amplitudes A1 and/or A2 are(e.g., corresponding to a deeper or more varying decorative pattern402), the more stretched out or thinner the formliner material will beafter formation of the formliner 100. In such cases, the materialthickness T1 of the formliners 100 may be increased to accommodate thelonger length H1″ while mitigating or substantially preventingundesirable manufacturing defects. A complicated decorative pattern 402may also require a relatively larger or thicker material thickness T1.

The material thickness T1 of the formliners 100 may determine the lengthor width W3 (FIG. 18) of the channel 170. The thicker the materialthickness T1 of the formliner 100, the longer or larger the width W3 ofthe channel 170 may have to be to accept, engage, mate, and/or connectwith the rib edge 241 as discussed herein. The width W3 of the channel170 may be designed to have a zero plus tolerance relative to thematerial thickness T1 of the formliner 100 to accept, engage, mate,and/or connect with the rib edge 241 as discussed herein. For example,the width W3 of the channel 170 may be designed to substantially be thesame as, substantially be equal to, and/or greater than the thicknessT1. Accordingly, while the rib edge 241 may not have an interference fitwith the channel 170 in at least some portions, having a zero plustolerance of the width W3 relative to the thickness T1 may help ensureand help facilitate overlaying the overlapping section 130 onto theoverlapped section 120 as discussed herein (e.g., mitigate orsubstantially prevent situations where the rib edge 241 cannot beinserted into the channel 170 because width W3 is less than or smallerthan the thickness T1). In some implementations, the width W3 and thethickness T1 may be designed to provide an interference fit between thethird wall 240 and/or free end 241 with the channel 170.

Example dimensions of the formliner can include H1 being about ¾ inches,H1′ or H1″ being about ¼ to about ⅜ inches, and T1 being about 9/100 toabout 1/10 inches. Correspondingly, A1 can be about ¼ inches to about ⅜inches. A2 can be about 13/20 inches. W3 can be about 9/100 inches toabout 1/10 inches. H1 can be about ¼ inches to about 2 inches, includingabout ½ inches to about 1 inch, including the foregoing values andranges bordering therein. H1′ can be about ¼ inches to about 2 inches,including about ½ inches to about 1 inch, including the foregoing valuesand ranges bordering therein. H1″ can be about ⅛ inches to about 1.9inches, including about ½ inches to about 1 inch, including theforegoing values and ranges bordering therein. T1 can be about 1/25inches to about ½ inches, including about 3/50 inches to about ⅕ inch,including the foregoing values and ranges bordering therein. A1 can beabout ⅛ inches to about 1.9 inches, including about ½ inches to about 1inch, including the foregoing values and ranges bordering therein. A2can be about ⅛ inches to about 1.9 inches, including about ½ inches toabout 1 inch, including the foregoing values and ranges borderingtherein. W3 can be about 1/25 inches to about ½ inches, including about3/50 inches to about ⅕ inch, including the foregoing values and rangesbordering therein.

As shown in FIGS. 16-18, the rib edge 241 can extend downward into thecell 104 or cell volume 105 along the first wall 204 to extend into,near, or proximate to the perimeter 210. If the rib edge 241 does notengage the channel 170 (for example, if the rib edge 241 ends somewherealong the vertical extent or longitudinal length of the first wall 204without entering the channel 170), a substantially visible seam may beformed in the curable material along, for example, the first wall 204where the rib edge 241 would terminate. Conversely, if the rib edge 241were to extend up to the perimeter 210 but there was not a channel 170provided, it would be difficult and cumbersome to form/trim the rib edge241 such that the end of the rib edge 241 followed the contour/outlineof the textured pattern (decorative pattern 402) of the base 103 at theperimeter 210 when the formliners are assembled as discussed herein.Accordingly, such a cumbersome formation as well as assembly process mayintroduce seams into the formliner assembly that may be visible in thecurable material. As shown, the rib edge 241 of the third wall 240extends into the cell volume 105, and in particular into the channel170. The rib edge 241 may extend into the channel 170 such that it isadjacent or proximate a top interior surface of the channel 170 facingthe rib edge 241.

Many advantages arise from these configurations of the formliners 100B,100C. One advantage is a structurally sound interface that is convenientto assemble and to disassemble. For example, the overlapped section 120may have increased stiffness and weight bearing capabilities (e.g.,against the weight of the curable material) due in part to the thirdwall 224. The third wall 240 may extend downward as previously discussedand as shown in FIGS. 16-17 and thereby provide increased stiffness tothe overlapped section 120 along the length of the overlapped section120. Such increased step stiffness may facilitate handling of theformliners without deforming or otherwise damaging them. Further,increased stiffness of the overlapped section 120 may provide a morerobust interface that is less susceptible to deformation under theweight of the curable material therein by the third wall 224 (e.g., ribedge 221) abutting or resting on support/resting surface 406 asdiscussed herein and preventing/inhibiting vertical (e.g., downward)movement of the overlapped section 120 (and correspondingly, theoverlapping section 130) along a longitudinal length of the third wall224 that may be perpendicular to the base 103 or bottom surface 111 asdiscussed herein. For example, the third wall 224 may help inhibit thesecond walls 220, 230, the first and third walls 204, 240, and/or thefirst and third walls 205, 224 from becoming disjointed (e.g.,separating from being in direct contact with each other because ofkinking/bending) when the curable material is poured against theformliners 100. The curable material may expand or contract within thecells 104. Having the robust interface as shown will mitigate damage ordeformation due to this and other influences of the curable material.

Another advantage from the shown interface in FIGS. 16-18 is that thereis little or substantially no interference with the curable materialinside the cells. For instance, the rib edge 241 is securely engagedwithin the channel 170 to not enter the cell volume 105 and thereby, maynot interfere with the curable material within that cell 104 such as,for example, not form a seam in the curable wall along or within thecell volume 105. By extending the third wall 240 into the channel 170,there will be fewer or substantially no discontinuities visible in theresulting cured material pattern. For instance, the rib edge 241 of thethird wall 240 may align with a portion or portions of the first wall204 such that a continuous surface along the ribs 102 or boundary 115 isproduced when the two formliners 100C and 100B are assembled as shown.By forming a continuous surface, the resulting cured material will havefewer visible discontinuities or seams.

FIG. 17 is a cross-section view of a portion of the assembly 300 astaken along the line 17-17 as indicated in FIG. 14. The interface shownin FIG. 17 may have similar features and functionalities as that shownand described with respect to FIG. 16. However, the interface is betweenthe formliner 100A and the formliner 100B. As oriented in FIG. 17, theoverlapped section 120 and the overlapping section 130 are now onopposite sides as that shown in FIG. 16. However, similar features andfunctionalities may apply to the interface in FIG. 17 as those of FIG.16, and this view is shown to exemplify another interface for othersections of the formliners.

FIG. 18 is a cross-section view of a portion of the assembly 300 astaken along the line 18-18 as indicated in FIG. 14. As shown, theformliner 100B may interface with the formliner 100C. The interfaceshown in FIG. 18 may have similar features and functionalities as thatshown and described with respect to FIGS. 16 and 17. As shown, theinterface as described herein with respect to FIGS. 16 and 17 may beimplemented without utilizing a third wall 224. As shown, a channel 170may be provided in an overlapped section 120C to interface with anoverlapping section 130B of the rib system 112. A third wall 224 may beprovided around, nearby, or proximate to the interface shown in FIG. 18.

As shown, the channel 170 may connect the internal section 108B to theoverlapped section 120B. Therefore, the ribs 102 of the formliner 100Bmay include an overlapped section 120B extending toward and connectingwith the channel 170, which in turn may connect with the internalsection 108B. As shown, the top surfaces of the overlapping section 130Cand the internal section 108B form a generally continuous surface. Thus,the channel 170 may provide a means by which two adjacent formliners mayform a substantially continuous surface. By “substantially continuous”it is meant that the resulting pattern formed using the assembledformliners would be acceptable to one of ordinary skill in the art(e.g., minimized or substantially absent seam formed in the curablematerial). Therefore, there may be a small gap in between adjacentformliners at, near, or proximate to the channel 170. The channel 170allows the formliner 100B to receive the formliner 100C such that theoverlapping section 130C is generally coplanar with the internal section108B (e.g., external surfaces of the ribs 102 are substantially flush).As shown, the overlapping section 130C may be at least partially on topof the overlapped section 120B.

FIG. 19 is a cross-section view of a portion of an other assembly 300 astaken along the line 18-18 as indicated in FIG. 14. As shown, theformliner 100B may have a transition zone 107B as discussed herein. Theformliner 100B may interface with the formliner 100C at the transitionzone 107B. The transition zone 107B may be an area or region of theformliners where adjacent formliners interface with each other whenassembled together. As shown, the transition zone 107B of the formliner100C may include a vertical step (or variable cross-section transition)between the internal rib section 108B and the overlapped section 120B.However, the transition zone 107B need not be a vertical step. Thetransition zone 107B may be a variety of other configurations, such asangled, rounded, multiple segments, other shapes, or combinationsthereof. However, other configurations are possible. The transition zone107 may be an angled step, a rounded feature, other shapes, orcombinations thereof. The transition zone 107 may provide a transitionbetween portions of the rib 102 with different cross-sections. Thetransition zone 107 may provide a transition between portions of the rib102 that are at different relative heights or lengths with respect toeach other. Therefore, the configuration shown is merely one possibletransition zone and many others may be implemented.

As shown, the transition zone 107B may connect the internal section 108Bto the overlapped section 120B. Therefore, the ribs 102 of the formliner100B may include an overlapped section 120B extending toward andconnecting with the transition zone 107B, which in turn may connect withthe internal section 108B. Further, as shown the two adjacent sectionsof the transition zone 107B may be at different heights. The internalsection 108B may be at a higher height (e.g., different or longer lengthor distance from a base 103 and/or support surface 406) than theoverlapped section 120C as oriented in FIG. 19. The internal section108B may be at a higher height than the overlapped section 120C suchthat the internal section 108B will form a substantially continuoussurface with the adjacent formliner 100C when assembled together.

As shown, the top surfaces of the overlapping section 130C and theinternal section 108B form a generally continuous surface. Thus, thetransition zone 107B may provide a means by which two adjacentformliners may form a substantially continuous surface. By“substantially continuous” it is meant that the resulting pattern formedusing the assembled formliners would be acceptable to one of ordinaryskill in the art (e.g., minimized or substantially absent seam formed inthe curable material). Therefore, there may be a small gap in betweenadjacent formliners at the transition zone 107B.

As shown, the transition zone 107B allows the formliner 100C to receivethe formliner 100C such that the overlapping section 130C is generallycoplanar with the internal section 108B (e.g., external surfaces of theribs 102 are substantially flush). As further shown, the overlappingsection 130C may be at least partially on top of the overlapped section120B. Further, as shown the upper and lower portions of the transitionzone 107B as oriented may have generally the same contour. That is, boththe upper and lower surfaces of the transition zone 107B may have asimilar vertical step, or other similar contour. However, this may notbe the case. The upper and lower portions of the transition zone 107Bmay have different contours. The upper portion of the transition zone107B may have a vertical step as shown, while the lower portion may havea different contour. For example, the upper portion of the transitionzone 107B may have the vertical step as shown while the lower portion ofthe transition zone 107B may have an angled, rounded or other contour.Furthermore, the lower portion of the transition zone 107B need not haveany transition at all. For instance, the lower portion of the transitionzone 107B may merely be a continuation of the lower surface of theoverlapped section 120B. While the transition zone 107C as shown anddescribed in FIG. 19 has been taken at one particular location of theassembly 300, it is understood that the features and functionalitiesdescribed with respect to this transition zone 107B may apply equally toother transition zones of the assembly 300.

FIG. 20 is an exploded view of an assembly of two adjacent formliners100E and 100F. The formliner 100E may include a boundary 115E which mayinclude an overlapped section 120E extending along a portion thereof.The formliner 100F may include a boundary 115F that may have anoverlapping section 130F extending along a portion thereof. Theoverlapped section 120E of the formliner 100E and the overlappingsection 130F of the formliner 100F may be brought into contact orotherwise adjacent to one another. The overlapping section 130F mayreceive the overlapped section 120E. By “receive” it is meant that theoverlapping section 130F may be overlaid (e.g., engaged, mated, coupled,assembled, connected and/or interconnected) onto or otherwise next tothe overlapped section 120E.

The formliner 100E may be assembled with the formliner 100F by bringingthe respective overlapped sections 120E and overlapping sections 130Ftogether. The respective sections may be brought together in a varietyof manners. The formliner 100E may be laid down on a platform of aframework, described in further detail herein, for example with respectto FIG. 22. The formliner 100F may be lowered onto the formliner 100Esuch that the overlapping section 130F overlaps with the overlappedsection 120E. The formliner 100E may be laid down first and then theformliner 100F may be slid adjacent to the formliner 100E. Therefore,the various formliners may be brought together in a variety of ways.When the formliner 100F is brought together with the formliner 100E, thethird corner 143F of the formliner 100F may be adjacent to the secondcorner 142E of the formliner 100E.

When the two formliners 100E, 100F are brought together, the overlappingsection 130F of the formliner 100F may be adjacent to and engaged withthe channel(s) 170E of the formliner 100E as discussed herein. Theoverlapping sections 130F of the formliner 100F may form a substantiallycontinuous surface (e.g., substantially flush exterior surfaces of theribs 102) with portions of the internal section 108E of the formliner100E. Further, when the formliner 100E and the formliner 100F areassembled together, they may appear, for example, similar to theformliners 100A and 100D shown in FIG. 14, or similar to the formliners100B and 100C as shown in FIG. 14.

As shown in FIG. 20, the two formliners 100E, 100F have complementaryfingerjoint patterns. The fingerjoint pattern of formliner 100E extendsfrom the third corner 143E along the overlapped section 120E. A portionof this fingerjoint pattern is shown. Similarly, the fingerjoint patternof formliner 100F extends from the second corner 142F along theoverlapping section 130F. A portion of this fingerjoint pattern isshown. The two fingerjoint patterns are complementary to each other suchthat when the two formliners 100E, 100F are brought together they willform an elongated formliner assembly that is longer than any oneindividual formliner 100E, 100F.

FIG. 21 is an exploded view of three formliners 100E, 100F, 100Gassembled together. The formliners 100E and 100F may be assembled in asimilar manner as described with respect to FIG. 20. The formliner 100Gmay be assembled with the formliners 100E and 100F. As discussed above,the third corner 143F of the formliner 100F may be adjacent to thesecond corner 142E of the formliner 100E when the three formliners 100E,100F, 100G are assembled together. As shown, the fourth corner 144F ofthe formliner 100F may be adjacent to the second corner 141E of theformliner 100E when the three formliners 100E, 100F, 100G are assembledtogether. Further, the overlapping section 130G of the formliner 100Gmay be adjacent to the portion of the overlapped section 120E of theformliner 100E that is adjacent to the overlapping section 130G asoriented in the figure. Therefore, the portion of a boundary 115G of theformliner 100G may be adjacent to this portion of the overlapped section120E of the formliner 100E when the three formliners 100E, 100F, 100Gare assembled together.

The formliner 100E and the formliner 100F may first be assembledtogether and then the formliner 100G may be assembled with the twoassembled formliners 100E, 100F. In some implementations, the formliner100E and the formliner 100G may first be assembled together and then theformliner 100F may be assembled with the two assembled formliners 100E,100G. A fourth formliner can be assembled after assembling formliner100G such that the fourth formliner couples with formliners 100F, 100Gas discussed herein. However, this is merely one example. The formliner100E may first be assembled with the formliner 100G, and then theformliner 100E may be assembled with the formliner 100F. The formliners100E, 100G may be laid down on a platform of a framework, and then theformliner 100F (before or after the fourth formliner) may be assembledsimultaneously with the formliners 100E, 100G. These are merely someexamples of how the formliners may be assembled together, and many othersuitable assemblies maybe implemented.

The formliner 100G may also include an overlapped section 120G as shown.This overlapped section 120G may be assembled with an overlappingsection of the fourth formliner as discussed herein.

FIG. 22 is a perspective view of an assembly 600 including variousformliners and a framework 602. The formliners may be assembled togetherwith the framework 602 in order to orient the formliners properly. Theframework 602 may further constrain or substantially prevent/inhibitmovement of the formliners in a desired position while the curablematerial is poured thereon to form a pattern.

The framework 602 may include a perimeter segment 604 that encloses theformliners therein. The perimeter segment 604 may be a wall as shownthat may enclose the formliners therein and/or substantiallyprevent/inhibit the curable material from spilling outside the framework602. The perimeter may have a height (e.g., vertical length) greaterthan a height (e.g., vertical length) to substantially prevent/inhibitthe curable material from spilling outside the framework 602. Theperimeter segments 604 may be “two by fours.” There may be three or fourperimeter segments 604 that form, respectively, a partially or fully anenclosed space therein.

The assembly 600 may include a platform 606 (e.g., a backing, base,bottom, support surface, plane, including support surface 406 asdiscussed herein). The perimeter segments 604 may be on or adjacent tothe platform 606. The platform 606 may be a generally planar surface onor to which the formliners may be positioned or attached. The platform606 may be sheet-metal or plywood or other suitable materials to whichthe perimeter segments 604 may be connected and on which the formlinersmay be received. Bottom surfaces 111 and/or third walls 240 (e.g., freeends 241) may wholly, partially, substantially contact, abut, comeagainst the platform 606 to provide support, structural integrity(substantially resistance to deformation given a desired curablematerial), and weight bearing capabilities to the respective formliners.For example, where the base 103 (and correspondingly the bottom surface111) may have a textured patterns such that some portions or parts ofthe bottom surface 111 contact the platform 606.

It is understood that while three perimeter segments 604 are shownattached to the platform 606, another perimeter segment 604 may also beconnected to enclose the formliners on all lateral sides of the platform606. Further, the assembly of the various perimeter segments 604 may allbe made from the same continuous, monolithic piece of material.

The assembly 600 may include the formliners 100H, 100I, 100J. Theformliner 100H may be positioned next to the formliner 100I within theframework 602. A boundary 115H of the formliner 100H may be contactingone or more of the perimeter segments 604 of the framework 602.Similarly, a boundary 115I of the formliner 100I may contact one or moreof the perimeter segments 604. The boundaries of the formliners maycontact the framework 602 in more than one location. For example, theboundary 115I of the formliner 100I may contact the perimeter 604 of theframework 602 along two sides of the formliner 100I. One end of theformliner 100I with a fingerjoint pattern along the boundary 115I maycontact one perimeter segment 604 of the framework 602, while anotherside of the formliner 100I at a different part of the boundary 115I maycontact a different perimeter segment 604 of the framework 602. Asshown, projecting cells 104 adjacent or near the perimeter segment 604can be trimmed or cut such that a continuous pattern may be formed inthe curable material starting from the perimeter segments 604.

A third formliner 100J may be assembled with the two formliners 100H,100I within the framework 602. As shown, the formliner 100J may have aboundary 115J which may be brought to contact the boundary or boundariesof the other formliners in the framework. For example, the boundary 115Jmay be brought to contact the boundary 115I of the formliner 100I. Theboundary 115J may also be brought to contact various portions of theframework 602. For example, a portion of the boundary 115J may bebrought to contact the perimeter segment 604 of the framework 602. Theformliner 100J may also be brought to rest on the platform 606 of theframework 602. The boundary 115J of the formliner 100J may thereforepartially contact the boundary 115I of the formliner 100I and partiallycontact one or more of the perimeter segments 604 of the framework 602.The boundary 115J of the formliner 100J may be brought to contact theboundary 115H of the formliner 100H. These are merely some examples ofhow the assembly 600 may be assembled, and other suitable configurationsmay be implemented. Similarly, a fourth or many more formliners may bejoined within the framework 602.

While there has been illustrated and described what are presentlyconsidered to be example embodiments, it will be understood by thoseskilled in the art that various other modifications may be made, andequivalents may be substituted, without departing from claimed subjectmatter. Additionally, many modifications may be made to adapt aparticular situation to the teachings of claimed subject matter withoutdeparting from the central concept described herein. Therefore, it isintended that claimed subject matter not be limited to the particularembodiments disclosed, but that such claimed subject matter may alsoinclude all embodiments falling within the scope of the appended claims,and equivalents thereof.

It is contemplated that various combinations or subcombinations of thespecific features and aspects of the embodiments disclosed above may bemade and still fall within one or more of the inventions. Further, thedisclosure herein of any particular feature, aspect, method, property,characteristic, quality, attribute, element, or the like in connectionwith an embodiment can be used in all other embodiments set forthherein. Accordingly, it should be understood that various features andaspects of the disclosed embodiments can be combined with or substitutedfor one another in order to form varying modes of the disclosedinventions. Thus, it is intended that the scope of the presentinventions herein disclosed should not be limited by the particulardisclosed embodiments described above. Moreover, while the inventionsare susceptible to various modifications, and alternative forms,specific examples thereof have been shown in the drawings and are hereindescribed in detail. It should be understood, however, that theinventions are not to be limited to the particular forms or methodsdisclosed, but to the contrary, the invention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the various embodiments described and the appended claims.Any methods disclosed herein need not be performed in the order recited.

The ranges disclosed herein also encompass any and all overlap,sub-ranges, and combinations thereof. Language such as “up to,” “atleast,” “greater than,” “less than,” “between,” and the like includesthe number recited. Numbers preceded by a term such as “approximately”,“about”, and “substantially” as used herein include the recited numbers,and also represent an amount close to the stated amount that stillperforms a desired function or achieves a desired result. For example,the terms “approximately”, “about”, and “substantially” may refer to anamount that is within less than 10% of, within less than 5% of, withinless than 1% of, within less than 0.1% of, and within less than 0.01% ofthe stated amount. Features of embodiments disclosed herein preceded bya term such as “approximately”, “about”, and “substantially” as usedherein represent the feature with some variability that still performs adesired function or achieves a desired result for that feature.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art can translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations may be expressly set forth herein for sakeof clarity.

It will be understood by those within the art that, in general, termsused herein, are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.). It will be further understood by those within the art that if aspecific number of an introduced embodiment recitation is intended, suchan intent will be explicitly recited in the embodiment, and in theabsence of such recitation no such intent is present. For example, as anaid to understanding, the disclosure may contain usage of theintroductory phrases “at least one” and “one or more” to introduceembodiment recitations. However, the use of such phrases should not beconstrued to imply that the introduction of an embodiment recitation bythe indefinite articles “a” or “an” limits any particular embodimentcontaining such introduced embodiment recitation to embodimentscontaining only one such recitation, even when the same embodimentincludes the introductory phrases “one or more” or “at least one” andindefinite articles such as “a” or “an” (e.g., “a” and/or “an” shouldtypically be interpreted to mean “at least one” or “one or more”); thesame holds true for the use of definite articles used to introduceembodiment recitations. In addition, even if a specific number of anintroduced embodiment recitation is explicitly recited, those skilled inthe art will recognize that such recitation should typically beinterpreted to mean at least the recited number (e.g., the barerecitation of “two recitations,” without other modifiers, typicallymeans at least two recitations, or two or more recitations).Furthermore, in those instances where a convention analogous to “atleast one of A, B, and C, etc.” is used, in general such a constructionis intended in the sense one having skill in the art would understandthe convention (e.g., “a system having at least one of A, B, and C”would include but not be limited to systems that have A alone, B alone,C alone, A and B together, A and C together, B and C together, and/or A,B, and C together, etc.). In those instances where a conventionanalogous to “at least one of A, B, or C, etc.” is used, in general sucha construction is intended in the sense one having skill in the artwould understand the convention (e.g., “a system having at least one ofA, B, or C” would include but not be limited to systems that have Aalone, B alone, C alone, A and B together, A and C together, B and Ctogether, and/or A, B, and C together, etc.). It will be furtherunderstood by those within the art that virtually any disjunctive wordand/or phrase presenting two or more alternative terms, whether in thedescription, embodiments, or drawings, should be understood tocontemplate the possibilities of including one of the terms, either ofthe terms, or both terms. For example, the phrase “A or B” will beunderstood to include the possibilities of “A” or “B” or “A and B.”

Although the present subject matter has been described herein in termsof certain embodiments, and certain exemplary methods, it is to beunderstood that the scope of the subject matter is not to be limitedthereby. Instead, the Applicant intends that variations on the methodsand materials disclosed herein which are apparent to those of skill inthe art will fall within the scope of the disclosed subject matter.

1-125. (canceled)
 126. A formliner for use with curable material, theformliner comprising: a plurality of cells each configured to face thecurable material; a rib system comprising a plurality of ribs extendingalong at least two cells of the plurality of cells, the plurality ofribs forming at least parts of boundaries of the at least two cells; anda channel extending along a cell of the at least two cells, the channelpositioned between a cell of the at least two cells and a rib of theplurality of ribs, the channel extending through an other rib of theplurality of ribs between the at least two cells of the plurality ofcells, the channel extending from the rib of the cell to form a planarsurface extending straightly from the rib to the channel.
 127. Theformliner of claim 126, wherein the channel extends into the cell toform an edge between the cell and the channel.
 128. The formliner ofclaim 127, wherein the edge is spaced from the planar surface along anextent between the plurality of ribs, the extent being along the cell.129. The formliner of claim 127, wherein the edge is formed from thechannel connecting to the cell at substantially 90 degrees.
 130. Theformliner of claim 126, wherein the channel extends from the cell towarda surface configured to support the formliner.
 131. The formliner ofclaim 126, wherein the channel has a width generally corresponding to athickness of the formliner.
 132. The formliner of claim 126, wherein atleast some of the plurality of ribs are substantially polygonal shaped.133. The formliner of claim 126, wherein the formliner comprises a firstend and a second end, the first end being formed to include a firstfinger joint pattern and the second end being formed to include a secondfinger joint pattern that is complementary to the first finger jointpattern, wherein the first end is configured to be overlaid with thesecond end to connect two or more formliners.
 134. The formliner ofclaim 126, wherein at least some of the plurality of cells havedifferent sizes.
 135. The formliner of claim 126, wherein the pluralityof cells comprise opposing ends, the plurality of cells being arrangedin a plurality of rows with each layer having at least two cellsdisposed end-to-end.
 136. The formliner of claim 135, wherein cells of afirst row of the plurality of rows are offset from cells of a second rowof the plurality of rows.
 137. A formliner for use with curablematerial, the formliner comprising: a plurality of cells each configuredto face the curable material; a plurality of ribs extending along atleast two cells of the plurality of cells, the plurality of ribs formingat least parts of boundaries of the at least two cells; and a grooveconnecting at least a part of a cell of the at least two cells to a ribof the plurality of ribs, the groove extending along at least portionsof boundaries of the at least two cells, the groove extending into thecell to form an edge between the cell and the groove, the grooveextending through an other rib of the plurality of ribs between the atleast two cells of the plurality of cells.
 138. The formliner of claim137, wherein the groove extends from the rib to form a planar surfaceextending straightly from the rib to the groove.
 139. The formliner ofclaim 138, wherein the edge is spaced from the planar surface along anextent between the plurality of ribs, the extent being along the cell.140. The formliner of claim 137, wherein edge is formed from the grooveconnecting to the cell at substantially 90 degrees.
 141. The formlinerof claim 137, wherein the groove extends from the cell toward a surfaceconfigured to support the formliner.
 142. The formliner of claim 137,wherein the groove has a width generally corresponding to a thickness ofthe formliner.
 143. The formliner of claim 137, wherein an other rib ofthe plurality of ribs comprises a first wall extending upwardly from acell of the other rib, a second wall extending from the first wallsubstantially in parallel with an extent of the cell of the other rib,and a third wall extending downwardly from the second wall toward theextent of the cell of the other rib, and wherein the rib of theplurality of ribs comprises a fourth wall extending upwardly fromgroove, a fifth wall extending from the fourth wall substantially inparallel with an extent of the cell of the rib, and a sixth wallextending downwardly from the fifth wall toward the extent of the cellof the rib.
 144. A method for assembling formliners, the methodcomprising: connecting a first formliner with a second formliner byoverlaying at least a portion of an overlapping section of a rib of thesecond formliner onto at least a portion of an overlapped section of arib of the first formliner, the overlapping section of the rib of thesecond formliner configured to face curable material; and positioning atleast a portion of a first rib edge of the overlapping section of therib of the second formliner into a groove of the first formliner, thegroove of the first formliner extending between the rib of the firstformliner and a cell of the first formliner, the groove extending intothe cell of the first formliner to form an edge between the groove andthe cell of the first formliner, the cell of the first formlinerconfigured to face curable material.
 145. The method of claim 144,wherein the groove of the first formliner extends through a rib betweenthe cell of the first formliner and an other cell of the firstformliner, and further comprising positioning the at least a portion ofthe first rib edge of the overlapping section of the rib of the secondformliner into the extent of the groove through the rib connecting thecell and the other cell of the first formliner.
 146. The method of claim144, further comprising placing curable material against exteriorsurfaces of the first and second formliners to create a pattern in thecurable material.